BR112012020846B1 - Method and apparatus for producing carbon black - Google Patents

Abstract

METHODS FOR THE PRODUCTION OF TOBACCO BLACK USING PREHEATED SUPPLY LOAD AND APPARATUS FOR THE SAME. Methods for producing carbon black are provided which employ high temperature feed loading, temperatures exceeding about 300°C with fouling control. An apparatus for producing carbon black is also provided in accordance with these methods.

Description

BACKGROUND OF THE INVENTION

The present application claims the benefit of 35 U.S.C. §119(e) of US Provisional Patent Application No. 61/306,092, filed February 19, 2010, which is incorporated herein by reference in its entirety.

The present invention relates to methods for producing carbon black using preheated feedstock with fouling control. The present invention also relates to an apparatus for producing carbon black using preheated feedstock with fouling control. The present invention also relates to carbon black resulting from the processes of the present invention.

Carbon blacks are widely used, for example, as pigments in paint compositions, inks and the like, as fillers and reinforcing pigments in the composition and preparation of rubber compositions and plastic compositions, and for a variety of other applications. Carbon blacks are generally produced in a furnace-type reactor by reacting a hydrocarbon feedstock with hot flue gases to produce combustion products containing particulate carbon black. In the carbon black literature, this reaction between the flue gases and the hydrocarbon feedstock is generically referred to as pyrolysis.

A variety of methods for producing carbon blacks are generally known. In one type of carbon black furnace reactor, as shown in US Patent Number 3,401,020 to Kester et al. or US Patent Number 2,785,964 to Pollock, a fuel, such as hydrocarbon fuel, and an oxidant, such as air, are injected into a first zone and react to form hot combustion gases. A hydrocarbon feedstock in gaseous, vapor or liquid form is also injected into the first zone after the reaction of the hydrocarbon feedstock begins. The resulting flue gas mixture, in which the reaction is taking place, then passes into a reaction zone where completion of the reaction takes place to form carbon black. In another type of carbon black furnace reactor, a liquid or gaseous fuel is reacted with an oxidant, such as air, in the first zone to form hot combustion gases. These hot combustion gases pass from the first zone, downstream through the reactor, into a reaction zone and beyond. To produce carbon blacks, a hydrocarbonaceous feedstock is injected at one or more points in the path of the hot flue gas stream. Generally, the hydrocarbon feedstock is a hydrocarbon oil or natural gas. The first (or combustion) zone and the reaction zone may be divided by a throttle or zone of limited diameter that is smaller in cross-section than the combustion zone or reaction zone. The feed charge may be injected into the hot flue gas path upstream of, downstream of, and/or into the limited diameter zone. The hydrocarbon feedstock may be introduced in atomized and/or non-atomized form from within the flue gas stream and/or from outside the flue gas stream. Carbon black furnace reactors of this type are shown, for example, in reissue US Patent number 28,974 to Morgan et al. and US Patent numbers 3,922,335 to Jordan et al.

In generally known processes and reactors, the hot flue gases are at a temperature sufficient to effect the reaction of the hydrocarbon feedstock injected into the flue gas stream. In one type of reactor, such as US patent number 3,401,020 to Kester et al., above, feedstock is injected at one or more points in the same zone where flue gases are being formed. In processes or reactors of another type, injection of the feedstock takes place, at one or more points, after the flue gas stream has been formed. The mixture of feedstock and flue gases in which the reaction is taking place is sometimes referred to below throughout the order as “the reaction stream”. The residence time of the reaction current in the reaction zone of the reactor is sufficient to allow the formation of the desired carbon blacks. In any type of reactor, once the hot flue gas stream is flowing down through the reactor, the reaction takes place as the mixture of feedstock and flue gases passes through the reaction zone. After carbon blacks having the desired properties are formed, the temperature of the reaction stream is lowered to a temperature such that the reaction is stopped, and the carbon black product can be recovered.

Other patents such as US Patent Numbers 3,922,335 to Jordan and others; 4,826,669 to Casperson; 6,348,181 to Morgan; and 6,926,877 to Green, also show the processes for producing carbon black, including feedstock temperatures. Typical feed load temperatures at the point of entry to the reactor, as shown in US Patent Number 4,826,669, can range, for example, from 250°F to 500°F (121°C to 260°C).

The present researchers recognized that hydrocarbon feedstock temperatures in carbon black production approaching or exceeding approximately 300°C at or before the point of entry into the reactor would create a heightened risk of disruptive thermally induced fouling levels from the reactors. power supply and equipment supply pipelines. Furthermore, the present researchers believe that methods and systems for producing carbon black that can tolerate such hot feedstocks have not been previously developed, nor do they present the possible benefits of utilizing hot feedload operation as previously being fully realized or obtainable, until the development of the present methods and arrangements for producing carbon black.

SUMMARY OF THE PRESENT INVENTION

Therefore, a feature of the present invention is to provide increased feedstock preheat temperatures in carbon black production with control of thermally induced fouling of the feedstock pipelines at the increased feedstock temperatures.

Additional features and advantages of the present invention will be set forth in part in the description which follows, and in part will be apparent from the description, or may be learned by practice of the present invention. The objects and other advantages of the present invention will be realized and obtained by means of the elements and combinations particularly indicated in the description and appended claims.

To obtain these and other advantages and in accordance with the purposes of the present invention, as incorporated and broadly described herein, the present invention relates, in part, to a method of producing carbon black including preheating a feedstock yielding carbon black at a temperature greater than approximately 300°C to provide feedstock yielding preheated carbon black in this temperature range. The feed load may be heated to a temperature of at least 450°C, or from approximately 360°C to approximately 850°C, or other temperatures exceeding 300°C. The feedstock yielding preheated carbon black may be supplied from at least one feedstock supply pipeline to at least one feedload introduction point to the reactor. The feedstock yielding preheated carbon black is introduced through at least one introduction point into the reactor to combine with a stream(s) of heated gas to form a reaction stream in which carbon black is formed in the reactor. Carbon black in the reaction stream can be quenched for recovery. The present method includes one or more approaches to lessening the risk of thermally induced fouling of the feedstock supply pipes at the increased feedload temperature. These approaches can minimize scale formation (e.g., reduce coke deposits), remove surface scale deposits (e.g., increase coke removal), or a combination of both, on the inner walls of the line or load supply pipes. of feedstock to keep the feedstock supply lines in operable condition while transporting the preheated feedstock to the reactor. These fouling control approaches may include one or more (or any combination) of: - feeding the feedstock yielding carbon black at a speed of at least approximately 0.2 m/sec (or, for example, at least approximately 1 m/s, or at least approximately 1.1 m/s, or at least approximately 1.6 m/s, or at least approximately 2 m/s, or other speeds greater than approximately 0.2 m/s) through at least one heater that heats the feedstock yielding carbon black to obtain preheat. - pressurizing the feedstock yielding carbon black to a pressure greater than approximately 1000 kPa before entering at least one heater to preheat the feedstock yielding carbon black (or, for example, greater than approximately 2000 kPa, or greater than approximately 3,000 kPa, or greater than approximately 4,000 kPa, or from approximately 2,000 to approximately 18,000 kPa, or from approximately 3,000 to approximately 18,000 kPa, or other pressures greater than approximately 1,000 kPa), - supply of a total feed charge residence time of the feed charge yielding carbon black in at least one heater for preheating and the feed charge yielding carbon black preheated in the feed charge supply piping prior to introduction into the reactor less than approximately 120 minutes (or, for example, from approximately 1 s to approximately 120 minutes, or approximately 1 to approximately 60 minutes, or other dwell times shorter than approximately 120 minutes), - preheat the feed load in at least one heater operating at an average heat flux (from inner tube surface) greater than approximately 10 kW/m2 (or, for example, greater than approximately 20 kW/m2, or from approximately 20 to approximately 200 kW/m2, or other average heat fluxes greater than approximately 10 kW/m2), - providing a surface non-catalytic to thermal cracking or hydrocarbon polymerization in the inner walls contacting the feed load of the feed load supply piping, - periodic supply of at least one purge gas (e.g. steam, air, oxygen, CO2) including a oxidizer to carbon, through the feed load supply piping or any combination thereof.

The fouling control provided by the present invention may allow at least a portion of the feedstock preheating to be accomplished by heating the feedstock with reactor generated heat at elevated reaction temperatures. The feedstock preheat conditions and designs made feasible by the present invention can provide advantages and benefits, such as, for example, improved energy recovery, savings in raw material costs, increases in carbon black amounts, reduction in carbon dioxide emissions, reduction in SOx and/or NOx emissions, stable or continuous production of carbon black for industrially useful durations of time at elevated feed load temperature conditions, or any combination thereof. The process of the present invention can be considered a "greener" process compared to conventional processes due to one or more of these environmental advantages mentioned herein.

The present invention also relates to an apparatus for carrying out methods such as those described above. The apparatus includes at least one reactor for combining a stream of heated gas and at least one feed charge yielding high temperature carbon black to form a reaction stream in which carbon black is formed in the reactor. Also included is at least one controlled fouling feed charge supply pipeline to supply the feed charge yielding carbon black to at least one feed charge introduction point in the reactor to match the feed charge with the gas stream. heated, and at least one feedstock heater operable to preheat the feedstock yielding carbon black supplied to at least one feedstock supply pipeline at a temperature greater than approximately 300°C. The apparatus further includes at least one pump a) operable to pressurize the feedstock yielding carbon black at a pressure greater than approximately 1000 kPa before the feedstock is preheated to a temperature greater than approximately 300°C, or b) providing a feed charge velocity through at least one feed charge heater which preheats the feed charge yielding carbon black of at least approximately 0.2 m/sec, or c) both. A blast chiller to cool the carbon black in the reaction stream may be included. The reactor is operable to provide a feed charge dwell time in at least one feed charge heater and at least one feed charge supply pipeline prior to introduction into the reactor to the feed charge preheated to a temperature greater than approximately 300°C which is less than approximately 120 minutes. At least a portion of the feedstock preheating may be performed in the apparatus, for example, by directly or indirectly heating the feedstock with exothermic heat generated by or in the reactor. The apparatus may have the feed charge heater arranged, for example, in the reactor in the reaction stream, arranged in contact with a heated reactor wall, arranged in contact with reactor tail gas, arranged outside the reactor to exchange heat with fluid. heat received from a heat exchanger located in the reactor, or any combination of these arrangements using one or more feed load supply pipes. The feed load heater may be one or more waste gas fired heaters (from the same and/or different carbon black reactors) or any hydrocarbon based fuel, and/or may be an electric heater.

For purposes of the present invention, the "supply pipeline" or "at least one feed load supply pipeline" may be any conduit, tube, heat exchanger pipeline, heat exchanger channel, or other structure suitable for transport. of steam or liquid feedstock, or combinations thereof, through which the feedstock is transported to the reactor at the preheated temperature. The “supply pipe” can be of any diameter and/or length. For example, if feedstock is preheated to a temperature of 300°C while passing through the piping or coils of a heat exchanger and is then fed from the heat exchanger to the reactor via separate piping, at “at least one supply piping” would include the portion of the heat exchanger piping extending between the location along the piping within the heat exchanger at which the feed loading temperature has reached 300°C and the discharge end of the heat exchanger piping , and also the piping after the heat exchanger through which the preheated feed load travels to reach the reactor. “Control”, with respect to coking associated with the feed load, refers to at least reducing (or avoiding or decreasing) the level of coking that occurs without the preventive step(s).

It is to be understood that both the above general description and the detailed description that follows are exemplary and explanatory only and are intended to provide a further explanation of the present invention as claimed.

The accompanying drawings, which are incorporated into and form a part of this application, illustrate aspects of the present invention and together with the description, serve to explain the principles of the present invention. Similar numeral identifiers used in the figures refer to similar aspects.

BRIEF DESCRIPTION OF THE DRAWINGS

Figure 1 is a schematic diagram of a portion of a type of furnace carbon black reactor that may be used in a process of the present invention to produce carbon blacks. This carbon black reactor is only illustrative of reactors that may be used in the present invention.

Figure 2 is a schematic diagram of a portion of another type of furnace carbon black reactor that may be used in a process of the present invention to produce carbon blacks. This carbon black reactor is only illustrative of reactors that may be used in the present invention.

Figure 3 is a schematic diagram of a still otherwise reactor-type furnace carbon black portion that may be used in a process of the present invention to produce carbon blacks. This carbon black reactor is only illustrative of reactors that may be used in the present invention.

Figure 4 is a schematic diagram of a portion of an additional type of furnace carbon black reactor that may be used in a process of the present invention to produce carbon blacks. This carbon black reactor is only illustrative of reactors that may be used in the present invention.

Figure 5 is a schematic diagram of a process scheme that may be used in a process of the present invention to produce carbon blacks. This carbon black reactor scheme is used in the examples, but is only illustrative of the reactors that may be used in the present invention.

Figure 6 is a graph of feed load heat capacity (kJoule/kg.°C) versus feed load temperature (°C) used for raw material savings calculations in modeling described in the examples.

DETAILED DESCRIPTION OF THE PRESENT INVENTION

The present invention relates to the use of increased feedstock preheat temperatures greater than approximately 300°C in producing carbon black unimpeded by feedstock fouling problems. The present invention may be applicable to the production of carbon black on an industrial scale, or other production scales.

The present invention relates in part to a method for producing carbon black. The method may include introducing a stream of heated gas into a carbon black reactor. The method further includes providing at least one feedstock yielding carbon black having a first temperature below the preheat temperature to be achieved, such as below 300°C or below 275°C (e.g., 40°C). at 274°C, from 50°C to 270°C, from 70°C to 250°C, from 60°C to 200°C, from 70°C to 150°C, and the like) to at least one heater ( for example, at least two heaters, at least three heaters, and the like where the heaters may be the same or different from each other). The temperature of the power load entering at least one heater is below the target preheat temperature or temperature range. The feed load before being preheated can optionally travel at a first speed of at least approximately 0.2 m/s (for example, at least approximately 0.4 m/s, at least approximately 0.6 m /s, at least approximately 0.8 m/s, at least approximately 1 m/s, at least approximately 1.1 m/s, at least approximately 1.6 m/s, such as from 0.2 m/s at 4 m/s, from 1.1 to 3 m/s and the like). Other speeds may be used provided that other processing conditions are selected to control fouling and/or coking in the heater(s) and supply lines to the reactor.

The method includes preheating at least one feedstock yielding carbon black in at least one heater to a second temperature greater than approximately 300°C (e.g., at least 350°C, at least 360°C, at least 400°C, at least 450°C, at least 500°C, such as 300°C to 850°C, or from 360°C to 800°C, from 400°C to 750°C, from 450°C to 700 °C and the like) to provide a preheated carbon black-yielding feedstock, where (a) at least one carbon black-yielding feedstock has a velocity at least in one heater that is at least 0.2 m/ s, where velocity is calculated based on a feed load density measured at 60°C at 1 atm (101.33 kPa) and based on the smallest cross-sectional area of a feed load pipeline present at least in a heater. Since it can be very difficult to measure the speed of a feed load at such an elevated temperature, for purposes of the present invention, the speed as mentioned herein is based on these specific measurement conditions. Whatever the smallest diameter or smallest cross-sectional area present in the effective heater, that minimum cross-sectional area is used to determine velocity as mentioned herein for purposes of the present invention. Many heaters have the same diameter across every heater, but in the event that multiple diameters or cross-sectional areas are present in the heater(s), this condition is met. Speed is based on minimum cross-sectional area. The effective velocity through the feed charge heater may be generally faster than the velocity measured at 60°C at 1 atm (101.33 kPa).

In the method, the feed charge yielding carbon black may have a first feed charge dwell time in the heater of less than approximately 120 minutes (e.g., less than 100 minutes, less than 80 minutes, less than 60 minutes). minutes, less than 40 minutes, less than 30 minutes, less than 20 minutes, less than 10 minutes, such as 1 second to 119 minutes, 5 seconds to 115 minutes, 10 seconds to 110 minutes, 30 seconds to 100 minutes , 1 minute to 60 minutes, 5 minutes to 30 minutes and the like). For example, when referring to the figures, the first feed load dwell time would be, for example, the time that the feed load spends in heater 19 in Fig. 1 or heater 22 in Fig. 2.

The method may include supplying the feedstock yielding preheated carbon black to at least one feedstock introduction point to the carbon black reactor (e.g., at least one or two or three or four feedstock introduction points to the carbon black reactor). feed load), where the feed load yielding preheated carbon black has a second feed load dwell time measured from exiting the heater(s) to just before the point of introduction into the black reactor less than approximately 120 minutes (e.g. less than 100 minutes, less than 80 minutes, less than 60 minutes, less than 40 minutes, less than 30 minutes, less than 20 minutes, less than than 10 minutes, such as 1 second to 119 minutes, 5 seconds to 115 minutes, 10 seconds to 110 minutes, 30 seconds to 100 minutes, 1 minute to 60 minutes, 5 minutes to 30 minutes and the like). The first power load dwell time and the second power load dwell time combined are preferably 120 minutes or less (e.g. less than 100 minutes, less than 80 minutes, less than 60 minutes, less than than 40 minutes, less than 30 minutes, less than 20 minutes, less than 10 minutes, such as from 1 second to 119 minutes, from 5 seconds to 115 minutes, from 10 seconds to 110 minutes, from 30 seconds to 100 minutes , from 1 minute to 60 minutes, from 5 minutes to 30 minutes and similar). For example, with reference to the figures, the second feed load dwell time would be, for example, the time that the feed load leaves heater 19 in Fig. 1 or heater 22 in Fig. 2 to the point of introduction into the reactor, shown as entry point 16 in Figure 1 and Figure 2. The combination of the first power load dwell time and second power load dwell time would be the total power load dwell time.

The method may include combining the feedstock yielding preheated carbon black through at least one point(s) of introduction into the carbon black reactor with the heated gas stream to form a reaction stream in which carbon black is formed in the carbon black reactor.

The method may include quenching the carbon black in the reaction stream. Other post quench steps that are conventional in the manufacture of carbon black can be used in the methods of the present invention.

Optionally, if the feed load piping to the heater is approximately the same cross section as the supply piping through the heater, the feed load yielding carbon black may have a velocity in the heater(s) that is approximately equal to or greater (e.g. at least 1% greater, at least 2% greater, at least 3% greater, at least 5% greater, at least 7% greater, at least 10% greater, at least 100% greater, at least 200% higher, such as 1% to 200% higher or 20% to 100% higher and similar) than the first speed inlet to the heater(s).

The method of the present invention may include pressurizing the feedstock(s) supplying carbon black. The method may include pressurizing or using pressure for the feedstock(s) supplying carbon black such that preheating the feedstock yielding carbon black prevents vapor film formation at least in a heater, or before supplying the reactor with carbon black. The method of the present invention may include pressurizing the feedstock(s) supplying carbon black to a pressure, for example, greater than approximately 1000 kPa before entering at least one heater that preheats the power load yielding carbon black. This pressure may be at least 1,500 kPa, at least 2,000 kPa, at least 3,000 kPa, at least 4,000 kPa, such as from 1,000 kPa to 18,000 kPa or more, from 1,500 kPa to 15,000 kPa, from 2,000 kPa to 12,500 kPa, from 2,500 kPa to 10,000 kPa.

In the present invention, a method of producing carbon black may include introducing a stream of heated gas into a carbon black reactor. The method further includes providing feedstock yielding carbon black having a first temperature below the target preheated feedstock temperature, such as below 300°C or below 275°C (e.g., from 40°C to 274°C). °C, from 50 °C to 270 °C, from 70 °C to 250 °C, from 60 °C to 200 °C, from 70 °C to 150 °C and similar) for heater(s) in a first pressure greater than 1000 kPa. This pressure can be at least 1,500 kPa, at least 2,000 kPa, at least 3,000 kPa, at least 4,000 kPa, such as 1,000 kPa to 18,000 kPa or more, 1,500 kPa to 15,000 kPa, 2,000 kPa to 12,500 kPa, 2,500 kPa at 10,000 kPa.

The method may include preheating at least one feed load yielding carbon black in the heater(s), (e.g., at least two heaters, at least three heaters, and the like, where the heaters may be the same or different from each other) at a second temperature greater than approximately 300°C (e.g. at least 350°C, at least 360°C, at least 400°C, at least 450°C, at least 500°C, as 300°C to 850°C, or 360°C to 800°C, 400°C to 750°C, 450°C to 700°C and the like) to provide a feedstock yielding preheated carbon black , where (a) the feedstock yielding carbon black has a second pressure at least in one heater that is approximately equal to or lower (e.g., at least 1% lower, at least 2% lower, at least 3 % lower, at least 5% lower, at least 7% lower, at least 10% lower, at least 15% lower, at least 20% lower, such as 1% to 75% lower or from 3% to 20% m lower and similar) than the first pressure and (b) the feed charge yielding carbon black has a first feed charge residence time in the heater of less than approximately 120 minutes (e.g., less than 100 minutes, less than 80 minutes, less than 60 minutes, less than 40 minutes, less than 30 minutes, less than 20 minutes, less than 10 minutes, such as from 1 second to 119 minutes, from 5 seconds to 115 minutes , from 10 seconds to 110 minutes, from 30 seconds to 100 minutes, from 1 minute to 60 minutes, from 5 minutes to 30 minutes and similar).

The method may include supplying the preheated carbon black-yielding feedstock to at least one feedstock introduction point to the carbon black reactor, where the preheated carbon black-yielding feedstock has a second feed load dwell time from at least one heater to the point of introduction to the carbon black reactor less than approximately 120 minutes (e.g., less than 100 minutes, less than 80 minutes, less than 60 minutes, less than 40 minutes, less than 30 minutes, less than 20 minutes, less than 10 minutes, such as from 1 second to 119 minutes, from 5 seconds to 115 minutes, from 10 seconds to 110 minutes, from 30 seconds to 100 minutes, 1 minute to 60 minutes, 5 minutes to 30 minutes and similar); and where the first power load dwell time and the second power load dwell time combined are 120 minutes or less (e.g. less than 100 minutes, less than 80 minutes, less than 60 minutes, less than 40 minutes, less than 30 minutes, less than 20 minutes, less than 10 minutes, such as from 1 second to 119 minutes, from 5 seconds to 115 minutes, from 10 seconds to 110 minutes, from 30 seconds to 100 minutes, from 1 minute to 60 minutes, from 5 minutes to 30 minutes and similar).

The method may include combining the feedstock yielding preheated carbon black through the point(s) of introduction into the carbon black reactor with the heated gas stream to form a reaction stream in which carbon black is formed in the carbon black reactor. The method may include quenching the carbon black in the reaction stream.

The present invention may relate to a method for producing carbon black which includes introducing a stream of heated gas into a carbon black reactor. The method further includes providing at least one feedstock yielding carbon black having a first temperature that is below the target preheated feedstock temperature, such as below 300°C or below 275°C (e.g., from 40°C to 274°C, 50°C to 270°C, 70°C to 250°C, 60°C to 200°C, 70°C to 150°C, and the like) at least a heater (for example, at least two heaters, at least three heaters, and the like where the heaters may be the same or different from each other) at a first pressure greater than 1000 kPa. Optionally, the velocity entering the heater may be a first velocity of at least approximately 0.2 m/s (e.g., at least approximately 0.4 m/s, at least approximately 0.6 m/s, at least approximately 0.8 m/s, at least approximately 1 m/s, at least approximately 1.1 m/s, at least approximately 1.6 m/s, such as from 0.2 m/s to 2 m/s, from 0.4 to 1.8 m/s and the like).

The method includes preheating the feedstock yielding carbon black in the heater(s) to a second temperature greater than approximately 300°C (e.g., at least 350°C, at least 360°C, at least at least 400°C, at least 450°C, at least 500°C, such as 300°C to 850°C, or from 360°C to 800°C, from 400°C to 750°C, from 450°C to 700°C and the like) to provide a preheated carbon black-yielding feedstock, wherein (a) at least one carbon black-yielding feedstock has a speed in the heater(s) that is at least 0 .2 m/s, where the velocity is calculated based on a feed load density measured at 60°C at 1 atm and the smallest cross-sectional area of a feed load pipeline present in at least one heater, and (b) where at least one feedstock yielding carbon black has a second pressure on the heater(s) that is approximately equal to or lower (e.g., at least 1% lower, at least 2% lower , foot lo least 3% lower, at least 5% lower, at least 7% lower, at least 10% lower, at least 15% lower, at least 20% lower, such as 1% to 25% lower low or 3% to 20% lower and similar) than the first press, where the pressure can be calculated based on assuming the same cross-sectional area as the feed load moves during the first press and second press ( although in effective operation, the cross-sectional area may be the same or different). This determination mode can be used to properly compare pressure, although it is not mandatory.

The method may include providing the feedstock yielding preheated carbon black to at least one feedstock introduction point to the carbon black reactor and combining at least the feedstock yielding preheated carbon black through from the point(s) of introduction(s) into the carbon black reactor with the heated gas stream to form a reaction stream in which carbon black is formed in the carbon black reactor. The method may include quenching the carbon black in the reaction stream.

In the present invention, for any method, the mentioned target preheat temperatures are preferably an average temperature of the feedstock before introduction into the carbon black reactor. The mentioned feed charge preheat temperatures may be a maximum feed charge temperature or a minimum feed charge temperature prior to introduction into the carbon black reactor.

In the present invention, for any method, the target pressure mentioned is preferably an average pressure of the feedstock. The stated pressure of the feed load can be a maximum pressure of the feed load or a minimum pressure of the feed load.

In the present invention, for any method, the target speed mentioned is preferably an average speed of the feed load. The mentioned power load speed can be a maximum power load speed or a minimum power load speed.

In the present invention, for any method, the feedstock yielding carbon black can be or include settling oil, coal tar product, ethylene cracker scale, asphaltene-containing oil, or any hydrocarbon liquid with a specific gravity of approx. 0.9 to approximately 1.5 or higher (such as 0.9 to 1.3, or 1 to 1.2 and the like) or any combination thereof. The feedstock yielding carbon black may have an initial boiling point of approximately 160°C to approximately 600°C, such as from 160°C to approximately 500°C or 200°C to approximately 450°C or 215°C to approximately 400°C or similar.

Preheat can occur in any number of modes and no limitations are intended to be placed on the mode to achieve this. Preheating can take place on at least one heater (eg one, two, three or more). The heat source for the at least one heater can be any source, such as from one or more carbon black reactors, electrical heat, plasma heat, waste gas heat, waste gas combustion heat, fuels and/or heat from other industrial processes and/or other forms of heat, and/or any combination thereof. Preheating can occur where at least one heater partially or fully heats the feed load to the target preheat temperature for introduction into the reactor. One heater can achieve partial or full preheat, or two or more heaters can be used in sequence or other arrangements to achieve preheat (full or partial). If partial preheat is achieved by at least one heater, then the remaining preheat is performed by an additional or secondary heat source or additional heaters to finally achieve the target preheat temperature.

For example, preheating at least one feedstock yielding carbon black may include or be accomplished by heating the feedstock yielding carbon black in at least one heater that has a heat exchanger. The heat exchanger may be operating at an average heat flow greater than approximately 10 kW/m2 (such as greater than approximately 10 kW/m2 or greater than approximately 20 kW/m2 or greater than approximately 30 kW/m2 or greater than approximately 40 kW/m2, such as from approximately 10 kW/m2 to approximately 150 kW/m2 and the like).

Optionally, at least a portion of the preheat (or complete preheat) occurs in at least one heater that has heat at least partially (or fully) supplied by heat generated by the carbon black reactor receiving the load. preheated feed or other carbon black reactor(s) or both. At least one heater may be in heat exchange with at least a portion of the carbon black reactor receiving the preheated feedstock or a different carbon black reactor(s) or both. For example, at least one heater may contact the reaction stream in a carbon black reactor, for example, downstream of a chiller, where at least one heater may have a heat exchanger with walls heated by the reaction stream in a first side (e.g. outer wall) thereof and contacting the feed load yielding carbon black on an opposite side (e.g. inner wall) thereof. Optionally, at least one heater may include a heat exchanger that exchanges heat with the reaction stream in a carbon black reactor, where a flowable heat carrier flowing through the heat exchanger is heated, and the heat carrier passes through at least one heater positioned external to the reactor and operable to transfer heat from the heat carrier to the feedstock yielding carbon black. At least one heater may be at least partially (or fully) supplied with heat with carbon black waste gas (e.g. waste gas heat or heat generated by burning waste gas) from the carbon black reactor or a reactor( es) of different carbon black(s) or both, to heat the feedstock yielding carbon black. Preheating can be partially or fully accomplished using one or more plasma heaters or other heaters or heat sources.

The introduction of the heated gas stream into the reactor may include plasma heating a plasma-heatable gas stream in a plasma heater to supply at least a portion of the heated gas stream.

A carbon black plasma reactor can be used to receive the feedstock yielding preheated carbon black. By utilizing preheated feedstock, and optionally preheated carrier gas (such as optional N2 with O2 to control reactivity), the heating method in the reactor can be a non-combustion type and combine the use of preheating. indirect reaction of reagents and plasma heating to the required process temperature to form carbon black. The carrier gas may be preheated using conventional air heater technology and/or one of the heater assemblies described herein to preheat the feed load. A similar mount can be used for the carrier gas as an option. This method reduces electrical consumption compared to plasma heating alone, and can reduce raw material costs, reduce CO2 emissions and/or water consumption.

In the present invention, a non-catalytic surface may be used on some or all of the walls contacting the feedstock yielding carbon black from at least one heater and/or inner walls of at least one feedstock supply pipe supplying the feedstock. feedstock yielding preheated carbon black to the carbon black reactor(s). The surface may be non-catalytic for cracking (eg thermal cracking) or hydrocarbon polymerization.

In the present invention, the supply may include or be used to feed the feedstock yielding preheated carbon black through at least one feedstock supply pipeline that supplies the carbon black reactor(s) with , and the method may optionally further include periodically feeding a purge gas(es) which may be an oxidant to carbon through at least one feedstock supply line(s) yielding carbon black. The feed load supply piping leading from at least one heater that preheats the feed load may have a cross-sectional area (e.g. diameter) that is the same as or different from the supply piping that feeds the feed load. at least one heater (for example, may have a smaller or larger cross-sectional area).

In the present invention, the supply may include feeding the feedstock yielding preheated carbon black through at least one feedstock supply pipeline that supplies the carbon black reactor(s), and the method may include injecting the feedstock yielding preheated carbon black into the carbon black reactor with at least partial (or full) ignition (e.g., evaporation of feedstock, e.g. obtained by lowering the pressure) of the feedstock power supply rendering carbon black.

With the present invention, using one or more of the scale removal prevention or cleaning steps described herein, the feedstock yielding preheated carbon black and the stream of heated gas in the carbon black reactor can be combined so as to continuously form carbon black in the reactor for at least approximately 12 hours (e.g. for at least 24 hours, for at least 48 hours, for at least 72 hours, for at least one week, twice, one or more months).

The present researchers have recognized that hydrocarbon feedstocks heated to temperatures exceeding approximately 300°C in carbon black production are at great risk of organic fouling (e.g., coking and/or polymerization) of feedstock and /or heater(s) that would preheat the supply load. Feed load supply piping may be steel or other metal tube constructions that may be susceptible to organic fouling on their internal surfaces. Fouling, if left unchecked, can lead to significantly reduced flow capacity in the feed load supply pipelines, and eventually clogged reactor tubes and/or injectors.

Fouling has been identified in the development of the present invention as a major technical barrier to the use of high temperature feedstocks in carbon black production. Without wishing to be bound by any specific theory, organic fouling can be caused in carbon black feedstock at elevated feedstock temperatures due to at least two fouling mechanisms: film boiling and asphaltene-induced coking. In film boiling fouling, the feedstock is believed to evaporate and form a vapor film that can block heat transfer (i.e. critical heat flow), where the vapor film overheats and causes coke to form. in vapor phase pyrolysis reactions. Asphaltenes are constituents that commonly occur in crude oils, and also transport at least in part in a variety of carbon black feedstocks in varying concentrations that would pose fouling hazards in high temperature use (e.g. >300°C) . In asphaltene-induced coking, it is believed that asphaltenes in feedstock can undergo liquid phase pyrolysis where asphaltenes become thermally destabilized to radical forms when exposed to thermal cracking temperatures and combine to form insoluble, high-weight coke. molecular. Elevated feedstock temperatures, for example, can cause long-chain molecules in the feedstock to crack, forming highly reactive compounds that polymerize and encrust. Left unchecked, higher feed charge temperatures can tend to cause the asphaltenes in the feed charge to agglomerate and precipitate out onto the feed charge heater and supply piping surfaces. Other organic fouling mechanisms can be promoted by high temperature feedstock operation, such as catalytic coking which can be caused by nickel or iron catalyzed thermal cracking reactions of hydrocarbons, depending on the feedstock supply piping material. . Polymerization of conjugated feedstock olefins (e.g. promoted by metal such as iron, nickel and the like on the inner surface of the tube) is also believed to be a potential cause of coking depending on the feedstock chemistry. Insoluble coke or other organic fouling media as described above, if allowed to occur in a carbon black production scheme, would deposit from the feedstock onto inner walls of the feedstock supply pipes and reactor injectors and accumulate to clog lines, and thereby stop carbon black production for maintenance and/or repairs. The present invention combines anti-fouling approaches with elevated temperature feedstock operation to lessen the disc of such thermally induced residue from feedstock pipelines that would otherwise prevent stable, maintained carbon black production.

As determined by the present invention, a coking signal occurs when there is a rapid pressure drop in pressure leaving the heater during preheating of the feed load compared to the pressure at the heater inlet. Typically, there is a normal pressure drop when comparing the heater inlet pressure to the feed load pressure leaving the heater due to the feed load friction in the lines. However, as was seen in the development of the present invention, a fugitive pressure drop is a sign that coking is highly likely or will occur. In more detail, after steady state operation has taken place and feed load is flowing through the heater at the desired parameters/rate, a consistent or relatively consistent pressure for the feed load leaving the heater is established and, as mentioned above, that pressure is typically below heater inlet pressure due to frictional forces with the feed load. However, when vapor film formation is occurring and/or coking is beginning to occur, a fugitive or rapid pressure drop occurs for the heater outlet pressure to the feed load exiting the heater outlet. A change of 2% or more in pressure drop after steady state operation occurs can be a sign that steam is forming and that this will lead to coking. A fugitive pressure drop of 2% or more, 3% or more, 5% or more, 7% or more, 10% or more, 15% or more, 20% or more, such as 2% to 20% or more, it is a sign that steam is forming and that this will, in all likelihood, lead to coking. As a more specific example, one might have a heater inlet pressure of X for the feed load entering the heater, and after steady state operation has been reached, the heater outlet pressure (namely, the load pressure outlet leaving the heater) may have a pressure of X to (0.8)X, and that pressure, during non-coking operations, will essentially be maintained at this lower pressure during steady-state operations. If the parameters of the carbon black manufacturing process are changed, then, of course, the pressure can again change due to a change in parameters. However, in the example, steady state operations have been achieved, and therefore the pressure leaving the heater will essentially be maintained with little fluctuation (+/- 0% to 1.9%). During steady state operations, if the pressure of the feedstock leaving the heater (or pressure before entering the carbon black reactor) drops by more than 2%, such as the percentage drops noted above, this would be a drop in fugitive pressure, which means that steam is building up in the feed load piping and that coking is most likely to result. The methods of the present invention provide methods for producing carbon black that prevent vapor film formation (e.g., prevent vapor film formation that blocks transfer) and/or a fugitive pressure drop, and a clear indication of to prevent vapor film formation is to avoid a fugitive pressure drop as indicated here. As an additional example, a fugitive pressure drop during steady state operations could be a pressure change of 2% or more, which can occur in a time frame of 15 seconds to 1 hour, or 30 seconds to 30 minutes, or 1 minute to 10 minutes, and this is avoided by the methods of the present invention.

The fouling control strategies applied to the manufacture of carbon black of the present invention can reduce or prevent the rate of deposition of coke or other fouling medium on inner walls of the feed load supply piping, remove coke or other fouling agent. deposited, or both. Fouling rates in feedload supply pipelines that contain feedstocks heated to more than approximately 300°C can be reduced or avoided by one or more of the following approaches: using a higher feedload pressure, using a faster higher feed load, decrease the heat flow capacity of a feed load heater, coat feed load supply piping (including those in a feed load heater) with a surface layer of non-catalytic material, decrease dwell time of the feed load in high temperature sections, or any combination of these approaches. As indicated, the removal of coke from the feedstock supply pipes can be used as another or additional approach to scale control in the present invention. Coke deposits, if they occur in the supply pipeline, can be removed, for example, by periodically purging the supply pipelines with a purge fluid or gas, such as an oxidizer for carbon. Feed load pipelines can be shredded or mechanically cleaned to remove coke.

For any combination of these antifouling approaches that are used, an objective may be to minimize the rate of net scale that occurs in the feed load supply piping (i.e., the rate of deposition of coke minus the rate of any decoking (removal coke) implemented). The preheated feedstock yielding carbon black can be continuously introduced into a reactor to form carbon black in the reactor in a stable, non-rupturing mode (e.g., no fouling that clogs feedload supply pipes) for a duration. , for example, at least approximately 12 hours, or at least 18 hours, or at least approximately 24 hours, or at least approximately 30 hours or more (e.g., 12 hours to 8 months or more, 12 hours to 6 months, 12 hours to 3 months, 20 hours to 1 month). Estimated raw material cost savings for the process of the present invention, as based on modeling shown in the examples, is in excess of 10% when feed load is preheated to 500°C and in excess of 20% when feed load is preheated to 500°C. is preheated to 700°C, in stable operating mode provided without feed load fouling compared to a conventional feed load temperature (below 300°C). There are also two additional benefits of the present invention. One is a yield-increasing mechanism due to seed preformation in the pyrolysis process. A second efficiency-enhancing mechanism is due to the instantaneous auto-evaporation of the feed charge in the carbon black reactor without cooling the surrounding gas. Furthermore, the antifouling strategies of the present invention do not require chemical additives, which may be uneconomical and/or incompatible with carbon black products or processing.

As indicated, the feedstock can be heated to a temperature greater than approximately 300°C, or other temperatures exceeding 500°C using present scale control approaches. The feed load temperature, due to advances of the present invention, can be, for example, at least 310°C, at least 350°C, at least 375°C, at least 400°C, at least 425°C, at least approximately 450°C, or at least approximately 500°C, or at least approximately 550°C, or at least approximately 600°C, or at least approximately 650°C, or at least approximately 700°C, or at least approximately 700°C approximately 750°C, or at least approximately 800°C, or at least approximately 850°C, or from approximately 305°C to approximately 850°C, or from approximately 350°C to approximately 850°C, or from approximately 450°C to approximately from approximately 750°C, or from approximately 450°C to approximately 700°C, or from approximately 500°C to approximately 750°C, or from approximately 500°C to approximately 700°C. this feed load temperature is the temperature of the feed load that forms carbon black just after leaving the heater(s) used to preheat the feed load and/or before it is introduced into the carbon black reactor. The feed load temperature in this regard may be measured or felt at one or more points along the feed load supply piping from the point at which the feed load temperature has been raised to a value that exceeds approximately 300° C to the discharge end of the supply pipeline where feed load is introduced into the reactor. Such feed load supply piping includes any length of tubing in a material load heater at and after which the feed load temperature has been raised to a value exceeding approximately 300°C and prior to transport in a portion of Additional supply piping extending from the feed load heater to the reactor. As an option, the preheated feed load temperature can have an absolute minimum value in the preheated feed load supply piping not less than 301°C, and/or as an option, a maximum temperature variability in the piping. preheated power supply load may be, for example, ±20%, or ±10%, or ±5% or ±2.5% or ±1% or ±0.5%, considering all points along the along the power supply pipeline. These stated feed load temperatures can be used in combination with the various scale control process variables listed here.

Fouling control using the mentioned feed load speed, at least in part, may include feeding the feed load(s) at that speed to the heater and/or through the heater that preheats the feed load and/or through the pipeline supplying feed load to the reactor. The speed may be, for example, at least approximately 0.2 m/s, or at least approximately 0.5 m/s, or at least approximately 1 m/s, or at least approximately 1.6 m/s, or at least approximately 2 m/s, or at least approximately 3 m/s, or from approximately 0.2 m/s to approximately 10 m/s, or from approximately 1 m/s to approximately 7 m/s, or from approximately 1, 5 m/s to 3 m/s, or from approximately 2 m/s to approximately 6 m/s, or from approximately 3 m/s to approximately 5 m/s. the feed load speed is a linear speed with respect to the longitudinal axis of the pipe or other supply pipe structure. The feed load speed (first speed) is measured at the point of being introduced into the heater which preheats the feed load. The feed load speed through the heater(s) and/or after leaving the heater(s) may be equal to or different from the first speed and, for example, may be greater (e.g. at least 1% greater, at least 2% greater, at least 3% greater, at least 5% greater, at least 7% greater, at least 10% greater, at least 100% greater, at least 200% greater, as of 1% to 300% higher or 50% to 200% higher and similar). Velocity is measured or calculated based on a measured feed load density at 60°C in 1 atm (101.33 kPa) and based on the smallest cross-sectional area present in the feed load piping being measured. Such feedload supply piping may include any length of piping in a feedload heater at and/or after which the feedload temperature has been raised to a value exceeding approximately 300°C and prior to transport in a portion of additional supply piping extending from the feed load heater to the reactor. For example, the feed load speed may have an absolute minimum value in the feed load supply piping not less than 0.2 m/s, and/or optionally, a maximum variability of the feed load speed in the supply piping power load can be, for example, ±20%, or ±10%, or ±5%, or ±1%%, or ±0.5%, considering all points along the supply piping power load.

Fouling control using feedstock pressurization, at least in part, may include pressurizing the feedstock yielding carbon black, for example, at a pressure greater than approximately 1,000 kPa, or greater than approximately 2,000 kPa, or greater than approximately 3,000 kPa, or greater than approximately 4,000 kPa, or greater than approximately 5,000 kPa, or from approximately 1,000 to approximately 18,000 kPa, or from approximately 2,000 to approximately 18,000 kPa, or from approximately 4,000 to approximately 18,000 kPa, or from approximately 5,000 to approximately 18,000 kPa or more. The feed load pressures of the present invention are given as absolute pressures. Pressure (first pressure) is the pressure measured at the point before introduction into the heater for preheating. The pressure across the heater(s) that preheats the feed load and/or later to the point(s) of introduction into the reactor may be equal to or different from the first pressure, such as lower than the first pressure (e.g. at least 1% lower, at least 2% lower, at least 3% lower, at least 5% lower, at least 7% lower, at least 10% lower, at least 15% lower, at least 20% lower, such as 1% to 25% lower or 3% to 20% lower and similar). Gauge pressure measurements must be set to absolute values in a known manner to make comparisons with the ranges shown here. Feed load pressure may be measured or felt at one or more points along the feed load supply piping from the point at which the feed load temperature has been raised to a value that exceeds approximately 300°C to the discharge end of the supply pipeline where the feed load is introduced into the reactor. Such feedload supply piping may include any length of piping in a feedload heater at and after which the temperature of the feedload has been raised to a value exceeding approximately 300°C and prior to transport in a portion of additional supply piping extending from the feed load heater to the reactor. Pressure can directly trend with feed load temperature for scale control. For example, a feed load pressure of 1000 kPa may be adequate to control fouling at a feed load temperature of 300°C, whereas an increased pressure greater than 1000 kPa, such as 2000 kPa or more, can be most useful for providing the same level of fouling control if the feed load temperature is increased to 500°C, all other things being equal.

Fouling control utilizing a low total feed load dwell time can be utilized. The total feed charge dwell time may be the combined time spent on at least one heater for preheating including the time the feed charge yielding preheated carbon black spends prior to introduction into the reactor. The total dwell time may be, for example, less than approximately 120 minutes, or less than approximately 90 minutes, or less than approximately 60 minutes, or less than approximately 45 minutes, or less than approximately 30 minutes, or less than approximately 15 minutes or less than 10 minutes or less than 5 minutes or less than 4 minutes or less than 3 minutes or less than 2 minutes or less than 1 minute or less than 30 seconds, or less than 15 seconds, or approximately 1/60th minute to approximately 120 minutes, or approximately 0.5 minute to approximately 120 minutes, or approximately 1 minute to approximately 90 minutes, or approximately 2 minutes to approximately 60 minutes, or from approximately 3 minutes to approximately 45 minutes, or from approximately 4 minutes to approximately 30 minutes, or from 5 to 30 minutes, or from 5 to 40 minutes, or from 10 to 30 minutes, or from approximately 5 minutes to approximately 15 minutes. the dwell time can be an average value or a maximum value or a minimum value. The feed load dwell time can be determined from the point at which the feed load temperature has been raised to a value that exceeds approximately 300°C to the point where the feed load is introduced into the reactor. The dwell time may tend inversely with the feed load temperature. For example, a feed load dwell time of up to approximately 120 minutes can be tolerated without fouling problems at a feed load temperature of 310°C, while the dwell time can preferably be reduced to less than 120 minutes to provide the same level of scale control if the feed load temperature is increased to 500°C, all other things being equal.

Fouling control during feed load preheating, e.g. in a feed load heater, may include use of a heater operating at an average heat flux, e.g. greater than approximately 10 kW/m2 , or greater than approximately 20 kW/m2, or greater than approximately 30 kW/m2, or greater than approximately 50 kW/m2, or greater than approximately 100 kW/m2, or from approximately 10 kW/m2 to approximately 150 kW/m2 (or more), or from approximately 20 to approximately 150 kW/m2, or from approximately 30 to approximately 100 kW/m2, or from approximately 40 to approximately 75 kW/m2, or from approximately 50 to approximately 70 kW /m2. Operating at a higher heat flux can be viewed as a scale control measure, because the higher heat flux results in the feed load yielding carbon black for faster heating and/or allowing for a shorter dwell time. on the heater as less time is required to reach the target preheat temperature.

Fouling control using non-catalytic surface cracking (e.g. thermal cracking) and/or hydrocarbon polymerization on inner walls contacting the feed load of the feed load supply pipeline, at least in part, may include, for example, for example one or more protective coating layer(s), such as a ceramic coating (e.g. silica, alumina, chromium oxide).

Fouling control using periodic feeding into the pipeline of a purge gas through the feed load supply pipeline may include injecting an oxidant to carbon (e.g. CO2, oxygen, steam, air and steam mixtures) into the supply pipeline. supply load at an accessible point or points along the supply load pipeline. Purge gas may be introduced at a temperature of 150°C or higher or exceeding 300°C downstream of any liquid feed load pumping means. The steam velocity through the purge piping can be, for example, at least approximately 6 m/s. Any standing water from the feedstock can be eliminated so that the purge immediately blows the entire feedstock into the reactor. Purge gas may be introduced upstream of a feed load heater to further ensure all supply pipelines exposed to process temperatures in excess of 300°C are treated.

As indicated, scale control by removing coke from the feeder pipelines may include, for example, shredding or mechanical scraping. Fragmentation, for example, may involve cooling a coke-lined in-line pipeline so that at least some of the coke deposited on the inside of the tube peels off or otherwise breaks free from the inside walls of the tube as the tube contracts in size during cooling. Loose coke can be washed out of the tube, and the shredded tube is ready for use again. During shredding, the feed load can be diverted from the pipe to be shredded, such as using valves, through a feed pipe or alternate online feed pipes to the reactor provided in the apparatus. After being cleaned, the shredded tube is ready for use again. Another method of cleaning deposited coke out of the feed charge tubes may involve moving a mechanical scraper through the tube to mechanically remove the coke from the interior of the tubes. During mechanical scraping, the feed load can be diverted, such as using valves, through a feed line or alternate online feed lines to the reactor provided in the apparatus, during the time when the tube taken offline for cleaning is temporarily out. of service. Shredding and/or mechanical scraping, if used, may be carried out periodically on the feed load supply pipes.

The feedstock yielding carbon black that can be processed at elevated temperatures with fouling control using the present invention may generally include any oil or hydrocarbon liquid feedstock useful for producing carbon black. Suitable liquid feedstocks include, for example, unsaturated hydrocarbons, saturated hydrocarbons, olefins, aromatics and other hydrocarbons such as kerosenes, naphthalenes, terpenes, ethylene tars, coal tars, cracker residues, and aromatic cycle materials, or any combinations thereof. The feedstocks can be, for example, settling oil, coal tar product, ethylene cracker residue, asphaltene-containing oil, or any combination thereof. The type of feed load can affect scale behavior. Chemistry may vary between different types of feedstock and/or within one type of feedstock. Based on experience and laboratory testing, settling oil, coker oil, coal tars, and ethylene cracker residues, for example, can all foul at various temperatures above approximately 300°C. Ethylene Cracker Residues (ECR), for example, can be relatively high in asphaltenes. Other types of feedstock may also contain asphaltenes and/or have chemicals subject to other waste mechanisms.

(1) Carga de alimentação pré-aquecida antes do reator (2) Através do aquecedor com base em condições de teste de 60°C a 1 atm (3) Antes do aquecedorThe asphaltene content of the feedstock may be, for example, from 0% to approximately 30% by weight, or at least approximately 0.5% by weight, or at least approximately 1% by weight, or at least approximately 2% by weight, or at least approximately 3% by weight, or from approximately 1% to approximately 10% by weight, or from approximately 2% to approximately 7.5% by weight, or from approximately 2.5% to approximately 5% by weight , based on the total weight of the power supply. The feedstock may have an initial boiling point, for example from approximately 160°C to approximately 500°C, or from approximately 180°C to approximately 450°C, or from approximately 200°C to approximately 400°C, or from 225°C to approximately 350°C. The initial boiling point refers to the temperature at which the first component of the feedstock (of the feedstock) evaporates. The feed charge may have a mid-range boiling point, for example from approximately 380°C to approximately 800°C, or from approximately 400°C to approximately 500°C, or from approximately 425°C to approximately 475° C, or from 440°C to approximately 460°C. the mid-range boiling point refers to the temperature at which 50% of the feedstock components have evaporated. The feedstock may have a final boiling point, for example from approximately 600°C to approximately 900°C, or from approximately 625°C to approximately 725°C, or from approximately 650°C to approximately 700°C, or from 670°C to approximately 690°C. the final boiling point refers to the temperature at which 100% of the feedstock components have evaporated. Other early, mid-range and/or late boiling points may apply, depending on choice and feedstock chemistry. Exemplary ranges of combinations of scale control process variables are given in Table 1. Table 1

(1) Preheated feed load before reactor (2) Through heater based on test conditions from 60°C to 1 atm (3) Before heater

In view of the above-described guidance and other provided herein, appropriate combinations of process variables to provide fouling control for the preheated feed load supply pipelines can be determined in a straightforward manner by a skilled person.

The methods of the present invention can be used with furnace carbon black reactors with adaptations and modifications as listed herein. The methods of the present invention can be put into practice, for example, in a modular furnace carbon black reactor, also referred to as "staged". Stage furnace reactors that can be adapted or modified to practice the present invention are shown, for example, in US Patent Nos. 3,922,335; 4,383,973; 5,190,739; 5,877,250; 5,904,762; 6,153,684; 6,156,837; 6,403,695; and 6,485,693 B1, all of which are incorporated by reference in their entirety herein. The fouling control provided by the present invention may optionally allow at least a portion of the feedstock preheating to be performed by heating the feedstock with heat generated by the furnace reactor from one or more reactor locations. This benefit is illustrated in the following discussions with reference to various figures.

The present invention also relates to an apparatus for producing carbon black. The apparatus or system includes: a reactor for combining a stream of heated gas and at least one feed charge yielding carbon black to form a reaction stream in which carbon black is formed in the reactor; at least one feed load supply pipeline for supplying the feed load yielding carbon black to at least one feed load introduction point to the reactor to combine the feed load with the heated gas stream; at least one feedstock heater operable to preheat the feedstock yielding carbon black supplied in at least one feedstock supply pipeline to a temperature of at least approximately 300°C; at least one pump operable to pressurize the feedstock yielding carbon black at a pressure greater than approximately 1000 kPa before the feedstock is preheated to at least approximately 300°C and to provide a feedrate velocity in the feed load heater of at least approximately 0.2 m/s, or both; and a blast chiller to cool the carbon black in the reaction stream.

The apparatus is operable to provide a feed charge dwell time in at least one feed charge heater and at least one feed charge supply pipeline prior to introduction to the reactor to the feed charge preheated to at least approximately 300°C which is less than approximately 120 minutes.

The at least one feedstock heater may be as mentioned above and may be or include a heat exchanger operable to heat the feedstock yielding carbon black at an average heat flux greater than approximately 10 kW/m 2 .

The at least one feed charge heater may be positioned in the reactor to be contactable by the reaction current operable to heat the feed charge to a temperature of at least 300°C, such as at least 370°C. At least one feed load heater may be positioned in contact (directly or indirectly) with at least a portion of the reactor operable to heat the feed load to a temperature of at least 300°C, such as at least 370°C. At least one feed load heater may be or include a heat exchanger positioned in the reactor downstream of the shear cooler, where the heat exchanger includes walls adapted to be heated by the reaction stream on a first side thereof and adapted to be contacted by a feed load on an opposite side thereof before the feed load is supplied to at least one feed load supply pipeline, where the feed load is heatable to a temperature of at least 300°C, such as at least 370°C in the heat exchanger. The apparatus may include at least one heat exchanger for a flowing heat carrier positioned in the reactor to be contacted by the reaction stream, and at least one feed load heater is external to the reactor and operable to exchange heat from the heat carrier. in flow leaving the heat exchanger with the feed load on the feed load heater to heat the feed load to a temperature of at least 300°C, such as at least 370°C. At least one feed charge heater may be operable to exchange heat from a waste gas stream from a reactor (a reactor receiving the preheat feed charge or a different one) to heat the feed charge to a temperature of at least 300°C, such as at least 370°C. The apparatus may include a plasma heater operable to heat a plasma-heatable gas stream to supply at least a portion of the heated gas stream. The apparatus may include non-catalytic surface on some or all of the walls contacting the feed load of the feed load heater and/or inner walls contacting the feed load of at least one feed load supply pipe, where the surface is not catalytic to thermal cracking or hydrocarbon polymerization. The apparatus may include non-catalytic ceramic coating on the feed load contacting walls of the feed load heater and/or inner walls contacting the feed load of at least one feed load supply pipeline. The apparatus may include at least one source of purge gas, such as an oxidizer for carbon, and at least one purge gas introduction point into at least one operable load supply line to periodically purge at least one supply line. supply charge with the purge gas. The reactor may be operable to combine feed load and hot gas stream to continuously form carbon black in the reactor for at least approximately 12 hours.

As an example, Figure 1 shows a portion of a type of furnace carbon black reactor that may be used in a process of the present invention to supply carbon blacks where at least a portion of the preheat includes heating a feedstock. yielding carbon black with the reaction stream in the reactor to heat the feedstock to a temperature greater than approximately 300°C. One or more of the indicated fouling control approaches is applied to the process schematic shown in Figure 1 to support the use of such a preheated feed load.

Referring to Figure 1, the carbon black of the present invention can be produced in a carbon black furnace reactor 2, having a combustion zone 10, which has an optional zone of converging diameter, 11, a zone(s) injection of feed charge 12, and a reaction zone(s) 13. A first quench zone 14 follows the reaction zone 13. Diameters and working lengths of these various zones that can be used can be selected with reference to patents above are incorporated by reference. To produce carbon blacks, hot combustion gases are generated in the combustion zone 10 by reacting a gaseous or liquid fuel with an appropriate oxidant such as air, oxygen, mixtures of air and oxygen or the like. Suitable fuels for use in reacting with the oxidant stream in the combustion zone 10 to generate the hot flue gases include any readily combustible gas, steam and/or liquid streams such as natural gas, hydrogen, carbon monoxide , methane, acetylene, alcohols or kerosene. It is generally preferred, however, to use fuels having a high content of carbon-containing components and, in particular, hydrocarbons. The stoichiometric ratio of air to natural gas used to produce the carbon blacks of the present invention can be from approximately 0.6:1 to infinity or from approximately 1:1 (stoichiometric ratio) to infinity. To facilitate the generation of hot flue gases, the oxidant stream can be preheated. The stream of hot flue gas flows downstream from zones 10 and 11 into zones 12 and 13 and then 14. The direction of flow of hot flue gases is shown in Figure 1 by the arrow. Feed charge yielding carbon black 15 is introduced at point 16 located in zone 12. The feed charge may be introduced through a probe(s), radially inwardly through a plurality of openings positioned in the wall of zone 12 at point 16, or a combination of the two. The feed load can be introduced axially or radially through a probe(s) axially inserted through the burner anywhere in zones 11, 12 and/or 13 ("stinger" operation). Suitable for use herein as the types of hydrocarbon feedstocks that provide carbon black, which may be readily volatilizable under the reaction conditions, include the previously noted feedstocks. Burner/reactor tips may be more susceptible to erosion at high feed load temperatures. Materials such as STELLITE® 6 metal alloy, for example, can be used to extend tip life.

As shown in Figure 1, the carbon black yielding feedstock 15 is preheated to a temperature greater than approximately 300°C before being introduced into the reactor 2. The preheated carbon black yielding feedstock is provided at least one pipeline supplying feed load 17 to at least one feed load introduction point 16 in reactor 2. Upon introduction, the feed load combines with the heated gas stream to form a reaction stream to which carbon black is formed in the reactor. The carbon black in the reaction stream may be saturated in one or more zones. For example, in the quench location 18 of the quench zone 14, quench fluid is injected which may include water, and which can be used to completely or essentially completely stop the pyrolysis of the feedstock yielding carbon black, or only partially cool the feedstock without stopping the pyrolysis followed by a secondary quench (not shown) used to stop the pyrolysis of the feedstock yielding carbon black.

As also shown in Figure 1, the feed load heater may include a heat exchanger 19 (HXR), which may have heater walls (not shown), as used in known heat exchanger designs, heated by the reaction stream. on a first side thereof and contacting feed load on an opposite side thereof before the feed load is supplied to at least one feed load supply pipeline. As indicated, the feed load is heated in the heat exchanger to a temperature greater than approximately 300°C. Although shown downstream of a shear chiller, the feed charge heat exchanger may be located upstream of the shear chiller in the reaction stream, provided the heater is of construction that can tolerate and operate at preheat temperatures. -sudden cooling higher in the reactor. The feed charge heater may be arranged to be in physical contact with at least a portion of the reactor, for example, as a coil or piping housed in and or against and in contact with a heated reactor wall or walls, to heat the reactor. power load at a temperature greater than approximately 300°C. Although not shown in Figure 1, the heat exchanger can optionally heat the feed load to an intermediate temperature (e.g. above 250°C or 50°C to 350°C, or other temperatures below the target preheated temperature ) or be used to get the preheat temperature above 300°C, then an additional heat exchanger or heater external or internal to the reactor can be used to heat up to the final preheat temperature.

The reaction stream in the reactor may have a temperature on quenching, for example from approximately 600°C to approximately 2000°C, or from approximately 800°C to approximately 1800°C, or from approximately 1000°C to approximately 1500°C. C, or other elevated temperatures that reflect an extreme exothermic reaction that is generated in the furnace reactor. The present invention can provide feedstock heat exchange with the high exothermic heat generated by the reactions in the reactor without fouling problems originating in the feedstock supply pipes. The present invention thus may make it feasible to improve energy recovery and save raw material costs compared to conventional carbon black production operating at much lower feedstock temperatures.

As also shown in Figure 1, at least one pump 20 may be installed in-line in the feed load piping upstream of the feed load heater 19 used to raise the feed load temperature to a value exceeding 300°C. the pump can be used to pressurize the feed load before entering the feed load heater. In this way, the feed load can already be pressurized at the moment when the feed load temperature is increased to high values where the problems of fouling in the feed load supply piping could otherwise originate in the absence of pressurization or other approaches. of fouling control indicated. As the feed load can normally experience a pressure drop during passage through the feed load heater under normal operating conditions (e.g. a pressure drop from 0 to approximately 2000 kPa), depending on, for example, the design of the feed load heat exchanger and mode of operation, any pressurization applied to the feed load as a scale control measure must compensate for any pressure drop that may occur or can be expected to occur in a feed load heat exchanger, as well as any other drop in pressure. pressure that occurs or can be expected to occur in the supply piping tubes or other conduits used to transport the preheated feed load to the reactor, particularly if necessary to maintain the feed load pressure within a pre-target range value . Although only a single feed load supply pipe and feed load injection point in the reactor is illustrated in Figure 1, and in other figures here, for the purpose of simplifying the illustrations, it is understood that multiple load supply pipes feed lines and reactor injection points can be used to which the indicated fouling controls can also be applied.

After the hot flue gas mixture and feedstock yielding carbon black is quenched, the cooled gases pass downstream in any conventional cooling and separation steps whereby the carbon black is recovered. The separation of the carbon black from the gas stream can be readily accomplished by conventional devices such as a precipitator, cyclone separator or bag filter. With respect to quenching the entire reactions to form the final carbon black product, any conventional process for quenching the reaction downstream of the introduction of the feedstock yielding carbon black can be used and is known to those skilled in the art. For example, a hard cooling fluid can be injected which can be water or other appropriate fluids to stop the chemical reaction.

Figure 2 shows a portion of another type of furnace carbon black reactor that may be used in a process of the present invention to produce carbon blacks where at least a portion of the preheat includes contacting a heat exchanger 21 with the reaction stream in the reactor where a flowing heat medium or carrier 28, such as steam or nitrogen, flowing through the heat exchanger is heated in the reactor, and the heated steam (e.g. superheated steam) then passes out of the heat exchanger. heat and reactor and is channeled through a separate feed load heater 22 positioned external to the reactor where operable to exchange heat with the feed load in the feed load heater to heat the feed load to a temperature greater than approximately 300°C. °C, such as 370°C or greater.

Figure 3 shows a portion of another type of furnace carbon black reactor that may be used in a process of the present invention to produce carbon blacks where at least a portion of the preheat includes contacting a feed charge heater 23. with residual gas exiting the reactor to heat the feed charge in the feed charge heater to a temperature greater than approximately 300°C (or at least partially to the target temperature).

Figure 4 shows another type of furnace carbon black reactor that can be used in a process of the present invention where the heated gas stream further includes at least in part or all of a heated gas 24 that has been heated at least in part or entirely using a plasma heater 25. Plasma heating of the gas can be carried out, for example, according to methods known to those skilled in the art. A plasma torch may be used, for example, as shown in US Patent Number 5,486,674, the entire disclosure of which is hereby incorporated by reference, and reference may be made to plasma heating shown in US Patent Numbers 4,101. 639 and 3,288,696, the entire disclosures of which are hereby incorporated by reference.

As also shown in Figure 4, the feedstock may be indirectly heated by a heating medium (e.g. steam) which has exchanged heat with the reaction stream in heat exchanger 26 in the reactor, or alternatively, the feedstock may be directly heated in the heat exchanger 26 in the reactor as shown by the dashed lines.

The heat exchanger design used to preheat the feed load, in or out of the reactor, in these various process schemes of the present invention can have any conventional heat exchanger design, such as shell and tube, shell and coil, plate and frame, and the like. Where the heat exchanger has an in-line coil configuration, 80 ratio tube and elbows can be used, eg for in-line coil to avoid erosion/corrosion issues. In addition, a constant pitch between tubes can be used in the construction of in-line coil piping, and the coil can utilize the entire cross-section of the combustible gas collector. Heat transfer coefficients for in-line coils can vary significantly for different types and different plants.

In addition, any of the feedstocks for the process schemes and methods described may contain additional materials or compositions that are commonly used to make conventional carbon black. The method of the present invention may further include introducing at least one substance that is or contains at least one Group IA and/or Group IIA element (or ion thereof) of the Periodic Table. The substance containing at least one Group Ia and/or Group IIa element (or ion thereof contains at least one alkali metal or alkaline earth metal. Examples include lithium, sodium, potassium, rubidium, cesium, francium, calcium, barium, strontium, or radium or combinations thereof. Any mixtures of one or more of these components may be present in the substance. The substance may be a solid, solution, dispersion, gas or any combination thereof. More than one substance having the metal of Group The same or different IA and/or Group IIa (or ion thereof) may be used. If multiple substances are used, the substances may be added together, separately, sequentially, or at different reaction sites. For purposes of the present invention, the substance may be the metal itself (or metal ion), a compound containing one or more of these elements, including a salt containing one or more of these elements, and the like. The substance may be capable of introducing a metal or metal ion in the reaction which is continued to form the carbon black product. For the purposes of the present invention, the substance containing at least one Group IA metal and/or Group IIa metal (or ion thereof), if used, may be introduced at any point in the reactor, for example, prior to complete quenching. For example, the substance can be added at any point before quenching completely, including before the introduction of the feedstock yielding carbon black in a first reaction stage; during the introduction of the feedstock yielding carbon black in a first reaction stage; after introduction of the feedstock yielding carbon black in a first reaction stage; before, during or immediately after the introduction of any second feed yielding carbon black; or any step after the introduction of a second feed charge yielding carbon black, but before full quenching. More than one substance introduction point may be used.

The amount of the Group IA metal and/or Group IIA metal (or ion thereof) containing substance, if used, can be any amount so long as a carbon black product can be formed. Substances may be added in an amount such that 200 ppm or more of the Group IA element or ion and/or Group IIA element (or ion thereof) is present in the finally formed carbon black product. Other amounts include approximately 200 ppm to approximately 20,000 ppm or more and other ranges may be from approximately 500 ppm to approximately 20,000 ppm, or from approximately 1,000 ppm to approximately 20,000 ppm, or from approximately 5,000 ppm to approximately 20,000 ppm, or from approximately 10,000 ppm ppm to approximately 20,000 ppm, or from approximately 300 ppm to approximately 5,000 ppm, or from approximately 500 ppm to approximately 3,000 ppm, or from approximately 750 ppm to approximately 1,500 ppm, of the Group IA and/or Group IIA element (or same) present in the carbon black product that is formed. These levels can be relative to the metal ion concentration. Such amounts of the Group IA element and/or Group IIA element (or ion thereof) present in the carbon black product that is formed may be with respect to one or more than one Group IA and/or Group IIA element (or ion thereof) and would therefore be a combined amount of the group IA and/or group IIA elements (or ions thereof) present in the carbon black product that is formed. Therefore, these amounts may apply to the Group IA element/ion or Group IIA element/ion content individually. The substance can be added in any way. The substance can be added in the same way that a feedstock yielding carbon black is introduced. The substance may be added as a gas, liquid or solid or any combination thereof. The substance can be added at one point or several points and can be added as a single stream or a plurality of streams. The substance may be mixed with the feedstock, fuel and/or oxidants prior to or during its introduction.

One method by which a substance containing at least one Group IA and/or Group IIA element (or ion thereof) such as, for example, potassium can be introduced into the feedstock is by incorporating the substance into the feedstock. In another method, the substance is introduced into the reactor separately from the feed charge, such as by using an injection wand that extends into the reactor. Addition of a potassium solution to the high temperature feedstock, for example, can create a risk of tip clogging, such as resulting from potassium scintillation. Injection of potassium or other group IA and/or II ions (or their ions) with a wand into the burner can be used to mitigate this risk. In addition, the use of a wand to introduce potassium to other Group IA and/or IIA metals (or metal ions thereof) into the reactor, which has openings larger than standard openings, can be done to reduce the risk of clogging or provide cleaning a wand in the load. To reduce the risk of burner liner damage when performing some high carbon black potassium ion ratings, the feed charge temperature may need to be lowered even lower in the range > 300°C so that potassium ions can be injected into the oil. For preheating the feedstock to > 300°C, an alternative oil-soluble form of potassium can be used, such as CATALYST® 460 HF, material from OM Group, which can be injected directly into the feedstock. The material of CATALYST® 460 HF is an organic salt of potassium (potassium neodecanoate), which is soluble in feedstock, therefore, it should not be subjected to the same risk of scintillation problems as with aqueous solutions. Therefore, the process schemes of the present invention based on high temperature feed loading and combined antifouling strategies can be adapted to be compatible with the use of in-process carbon black modifiers such as structure control additives (e.g. (e.g. potassium or other alkali metal/ion sources).

The feed load preheat conditions and designs made plausible by the present invention can provide advantages and benefits such as, for example, improved energy recovery, raw material cost savings, increases in carbon black, reduction of carbon dioxide emissions, stable or continuous production of black and carbon, production for industrially useful time periods under high feed load temperature conditions, or any combination thereof. Increasing the feed load preheat to more than 300°C can be expected to reduce sulfur and NOx emission levels based on a mass ratio under constant production conditions. The emission rate per kg of carbon black is expected to decrease under all operating conditions. The emission concentration depends on the specific operating conditions chosen.

In addition to the previously stated benefits and advantages, other potential benefits of the preheated feed load can be realized in accordance with the present invention. A yield increase mechanism may result from seed preformation in the pyrolysis process. While not wishing to be bound by a specific theory, the feedstock may be subjected to polycyclic aromatic hydrocarbon (PAH) dehydrogenation reactions and abstraction of non-aromatic groups during the preheating phase. Dehydrogenated PAHs are expected to form seeds faster than the parent material. High pressure was shown in the examples to control the rate of dehydrogenation. Pressure, residence time, and/or temperature control as detailed herein can control the formation of large PAH molecules, which would potentially be able to provide a control mechanism for carbon black seed production. As indicated, the disadvantage of a high temperature feedstock pyrolysis is the potential for coke and granule formation, which is attenuated or prevented in the present invention, where the high temperature conditions of the feedstock are combined with approaches on-site fouling control. A second mechanism for increasing yield may be, for example, by flash evaporation of the preheated feedstock in the carbon black reactor, without quenching the surrounding gas. Instantaneous scintillation evaporation from the feed charge would obviate the need to use combustion gas from the burner for feed charge atomization. When injected at near atmospheric pressure into the carbon black reactor, the feedstock preheated to temperatures exceeding 300°C can have sufficient internal energy to self-evaporate and mix with the combustion gases from the burner.

Any type of ASTM grade rating (eg N100 to N1000) or other carbon black ratings can be made by the present invention. The carbon black obtained by the processes of the present invention may have one or more unique properties (or beneficial properties) and/or parameters due to the use of high preheat feedstock temperatures and/or other process parameters mentioned herein. document. The carbon black obtained by the methods and equipment arrangements of the present invention can be used in any end-use application where conventional carbon blacks are used, for example, paints, pigments, plastic products, sealants, adhesives, coatings, elastomerics, toners, fuel cells, pneumatics or parts thereof, molded parts, electronic components, cables, wires, or parts thereof, and the like, using conventional or lesser amounts.

An advantage that can be achieved with the present invention is the formation of commercially acceptable carbon blacks having the same morphology and/or other parameters as carbon black obtained in a conventional manner. With the present invention, commercially acceptable carbon blacks exhibiting the same morphology and/or other parameters are capable of being obtained using the processes of the present invention. As an option, an advantage can be obtained with the present invention is the formation of carbon blacks which have a much lower amount of PAH. A lower amount of PAH in carbon blacks does not change the performance of the carbon black and, generally, a high amount of PAH is undesirable for a variety of reasons. With the present invention, a selected carbon black can be obtained having the same or essentially the same morphology (i.e., a morphology value within plus or minus 5% variation in one or more morphology properties or essentially the same morphology). same morphology, such as OAN, COAN and the like), as the selected carbon black obtained by a conventional method using the same reactor conditions and feed charges (but where preheating of the feed charge to higher temperatures does not occur at 300°C prior to supplying feed to the carbon black reactor). The PAH levels of a selected carbon black of the present invention can be reduced, on a ppm weight basis, from 10% to 50%, from 20% to 50%, or from 30% to 100% or more based on levels of ppm when compared to selected carbon black having the same morphology, but prepared where no preheating of the feedstock yielding carbon black to more than 300°C occurs prior to entering the carbon black reactor to form carbon black and using the same reactor and feed load conditions. In addition, PAH levels in carbon black can be separated into three molecular weight (MW) categories: high MW PAHs (greater than 250 MW average weight); Medium MW PAHs (200 to 250 MW average weight); and low MW PAHs (less than an average weight of 250 MW). The present invention has the ability to reduce one or more of the amounts of high and/or medium MW PAH from 10% to 50%, from 20% to 50%, or from 30% to 100% or more based on ppm levels when compared to a carbon black having the same morphology but prepared where no preheating of the feedstock yielding carbon black to more than 300°C prior to entering the carbon black reactor to form carbon black smoke and use the same reactor and feed load conditions. Furthermore, the present invention has the ability to greatly reduce the percentage of high MW PAHs (considered the most undesirable) from the total amount of PAH of a selected carbon black as compared to selected carbon black having the same morphology, but prepared where no preheating of the feedstock yielding carbon black greater than 300°C occurs prior to entering the carbon black reactor to form carbon black and using the same reactor and feed and feed conditions. The percentage of high MW PAHs from the total PAH amount can be reduced by amounts from 10% to 50%, from 20% to 50%, or from 30% to 100% or more based on the ppm levels of a black of selected carbon, when compared to selected carbon black having the same morphology, but prepared where no preheating of the feedstock yielding carbon black to more than 300°C occurs before entering the carbon black reactor to form black of smoke and using the same reaction conditions and feed load. The above determinations were made based on experiments that compared selected carbon blacks manufactured using the present invention to selected carbon blacks where no preheating of the charge and feed yielding carbon black to more than about 300°C occurs prior to inlet. in the carbon black reactor to form carbon black, but using the same reaction conditions and feed load. This is a significant advantage that can be obtained with the present invention.

The present invention includes the following aspects/modalities in any order and/or in any combination: 1. The present invention relates to a method for producing carbon black comprising: introducing a stream of heated gas to the carbon black reactor smoke; supplying at least one carbon black yielding feed to the at least one heater; preheating said at least one carbon black yielding feed in said at least one heater at a second temperature greater than about 300°C to provide a preheated carbon black yielding feedstock, wherein ( a) at least one feedstock yielding carbon black has a velocity in said at least one heater that is at least 0.2 m/s and the velocity is calculated based on the feedstock density measured at 60°C in 1 atm and the smallest cross-sectional area of a feed charge pipeline present in said at least one heater and (b) at least one feed charge yielding carbon black exhibits a first feed charge residence time in said heater. at least about 120 minutes; supplying a preheated carbon black-yielding feedstock to at least one carbon black introduction point to the carbon black reactor, wherein said preheated carbon black-yielding feedstock exhibits a second residence time leaving said at least one heater for just before the point of introduction to said carbon black reactor of less than about 120 minutes; and wherein said first feed load residence time and said second feed load residence time combined are 120 minutes or less; combining at least said feedstock yielding preheated carbon black through at least one point of introduction to said carbon black reactor with the heated gas stream to form a reaction stream in which the carbon black is formed in said carbon black reactor; and recovering (eg, quenching) the carbon black in the reaction stream. 2. The method of any foregoing or following embodiment/feature/aspect, further comprising pressurizing said feed charge yielding carbon black so that it has a pressure greater than about 1,000 kPa prior to entering said at least 1000 kPa. minus one heater. 3. The method of any foregoing or following embodiment/feature/aspect, further comprising pressurizing said feed charge yielding carbon black so that it has a pressure greater than about 2000 kPa prior to entering said at least minus one heater. 4. The method of any preceding or following embodiment/feature/aspect, further comprising pressurizing said feedstock yielding carbon black at a pressure between about 2000 kPa to about 18,000 kPa before entering said at least one heater. 5. The method of any preceding or following embodiment/feature/aspect, wherein said velocity is at least about 1 m/sec. 6. The method of any preceding or following embodiment/feature/aspect, wherein said velocity is at least about 1.6 m/sec. 7. The method of any preceding or following embodiment/feature/aspect, wherein said feedstock yielding carbon black comprises settling oil, coal tar product, ethylene cracking residue, asphaltene-containing oil, or any combination of these. 8. The method of any preceding or following embodiment/feature/aspect, wherein said feedstock yielding carbon black has an initial boiling point of from about 160°C to about 500°C. 9. The method of any preceding or following embodiment/feature/aspect, wherein said preheating at least one feedstock yielding carbon black comprises heating said feedstock yielding carbon black in said heater having a heat exchanger operating at an average heat flux greater than about 10 kW/m2. 10. The method of any preceding or following embodiment/feature/aspect, wherein at least a portion of said preheating takes place in said at least one heater which has its heat supplied, at least partially, by heat generated by the said carbon black reactor or another carbon black reactor or both. 11. The method of any preceding or following embodiment/feature/aspect, wherein said first residence time and second residence time combined are less than 60 minutes. 12. The method of any preceding or following embodiment/feature/aspect, wherein said at least one heater exchanges heat with at least a portion of said carbon black reactor. 13. The method of any preceding or following embodiment/feature/aspect, wherein said at least one heater contacts said reaction stream in said carbon black reactor downstream of a flash cooler, wherein said at least one heater comprises a heat exchanger, with walls heated by said reaction stream on a first side thereof and contacting said feed charge yielding carbon black on an opposite side thereof. 14. The method of any preceding or following embodiment/feature/aspect, wherein said at least one heater includes a heat exchanger that exchanges heat with said reaction stream in said carbon black reactor, wherein a heat carrier flowable heat exchanger flowing through the heat exchanger is heated, and the flowable heated heat carrier passes through said at least one heater positioned external to the reactor and operable to exchange heat from the flowable heat carrier with the feed load to heat said power load yielding carbon black. 15. The method of any preceding or following embodiment/feature/aspect, wherein said at least one heater is at least partially heated with carbon black tail gas from said carbon black reactor or a carbon black reactor of different carbon, or both, to heat the feedstock yielding carbon black. 16. The method of any preceding or following embodiment/feature/aspect, wherein introducing the heated gas stream comprises plasma heating a plasma heated gas stream in a plasma heater to provide at least a portion of the heated gas stream. 17. The method of any preceding or following embodiment/feature/aspect, further comprising providing a non-catalytic surface on the walls contacting the feed load yielding carbon black from said at least one heater and inner walls of at least a feedstock supply pipeline that supplies said feedstock yielding preheated carbon black to said carbon black reactor, where the surface is non-catalytic to cracking or hydrocarbon polymerization. 18. The method of any preceding or following embodiment/feature/aspect, wherein said supply comprises providing said feedstock yielding preheated carbon black through at least one feedstock supply pipeline which feeds said carbon black reactor, and said method further comprising periodically feeding a purge gas comprising an oxidant to carbon through the at least one feed charge supply line yielding carbon black. 19. The method of any preceding or following embodiment/feature/aspect, wherein said supply comprises feeding said feedstock yielding preheated carbon black through at least one feedstock supply pipeline which feeds said carbon black reactor, and said method further comprises injecting the preheated carbon black yielding feedstock into the carbon black reactor with at least partial scintillation of the carbon black yielding feedstock. 20. The method of any preceding or following embodiment/feature/aspect, further comprising combining the feedstock yielding preheated carbon black and the stream of heated gas in the carbon black reactor to continuously form carbon black. smoke in the reactor for at least about 12 hours. 21. A method for producing carbon black comprising: introducing a stream of heated gas into a carbon black reactor; supplying at least one feedstock yielding carbon black having a first temperature below 360°C to the at least one heater; preheating said at least one feedstock yielding carbon black in said at least one heater to a second temperature of from about 360°C to about 850°C to provide a feedstock yielding carbon black preheated, where (a) the at least one feedstock yielding carbon black has a velocity in said at least one heater that is at least 0.2 m/sec, and the velocity is calculated based on a density of feed load measured at 60°C at 1 atm and the smallest cross-sectional area of a feed load pipe present in said at least one heater, and (b) at least one feed load yielding black of smoke has a first feed load residence time in said heater of less than about 120 minutes; supplying said feedstock yielding preheated carbon black at at least one feedstock introduction point of the carbon black reactor, wherein said feedstock yielding preheated carbon black has a second residence time of feed load since leaving said at least one heater stops immediately before the point of introduction to said carbon black reactor of less than about 120 minutes, and wherein said first feed load residence time is said second combined feed load residence time are from about 10 seconds to about 120 minutes; combining at least said feedstock yielding preheated carbon black through at least one point of introduction to said carbon black reactor with the heated gas stream to form a reaction stream where carbon black is formed in the said carbon black reactor; and recovering (eg, by quenching) the carbon black in the reaction stream. 22. The method of any foregoing or following embodiment/feature/aspect, further comprising pressurizing said feed charge yielding carbon black so that it has a pressure greater than about 2000 kPa before entering said at least minus one heater. 23. The method of any foregoing or following embodiment/feature/aspect, further comprising pressurizing said feed charge yielding carbon black so that it has a pressure greater than about 3,000 kPa prior to entering said at least minus one heater. 24. The method of any preceding or following embodiment/feature/aspect, further comprising pressurizing said feedstock yielding carbon black at a pressure between about 3,000 kPa and about 18,000 kPa prior to entering said at least minus one heater. 25. The method of any preceding or following embodiment/feature/aspect, wherein said velocity is at least about 1 m/sec. 26. The method of any preceding or following embodiment/feature/aspect, wherein said velocity is at least about 1.6 m/sec. 27. The method of any preceding or following embodiment/feature/aspect, wherein said feedstock yielding carbon black comprises settling oil, coal tar product, ethylene cracking residue, asphaltene-containing oil, or any combination of these. 28. The method of any preceding or following embodiment/feature/aspect, wherein said feedstock yielding carbon black has an initial boiling point of from about 160°C to about 500°C. 29. The method of any preceding or following embodiment/feature/aspect, wherein said preheating at least one feedstock yielding carbon black comprises heating said feedstock yielding carbon black in said heater having a heat exchanger operating at an average heat flux greater than about 20 kW/m2. 30. The method of any preceding or following embodiment/feature/aspect, wherein at least a portion of said preheating takes place in said at least one heater which has its heat supplied, at least partially, by heat generated by the said carbon black reactor or another carbon black reactor or both. 31. The method of any preceding or following embodiment/feature/aspect, wherein said first residence time and second residence time combined are less than 60 minutes. 32. The method of any preceding or following embodiment/feature/aspect, wherein said at least one heater exchanges heat with at least a portion of said carbon black reactor. 33. The method of any preceding or following embodiment/feature/aspect, wherein said at least one heater contacts said reaction stream in said carbon black reactor downstream of a flash cooler, wherein said at least one heater comprises a heat exchanger, with walls heated by said reaction stream on a first side thereof and contacting said feed charge yielding carbon black on an opposite side thereof before said feed charge yielding carbon black. 34. The method of any preceding or following embodiment/feature/aspect, wherein said at least one heater includes a heat exchanger that exchanges heat with said reaction stream in said carbon black reactor, wherein a heat carrier flowable flowable heat exchanger is heated, and the flowable heated heat carrier passes through said at least one heater positioned external to the reactor and operable to exchange heat from the flowable heat carrier with the feed load to heat said power load yielding carbon black. 35. The method of any preceding or following embodiment/feature/aspect, wherein said at least one heater is at least partially heated with carbon black tail gas from said carbon black reactor or a carbon black reactor of different carbon, or both, to heat the feedstock yielding carbon black. 36. The method of any preceding or following embodiment/feature/aspect, wherein introducing the heated gas stream comprises plasma heating a plasma heated gas stream in a plasma heater to provide at least a portion of the heated gas stream. 37. The method of any preceding or following embodiment/feature/aspect, further comprising providing a non-catalytic surface on the walls contacting the feed load yielding carbon black from said at least one heater and inner walls of at least a feedstock supply pipeline that supplies said feedstock yielding preheated carbon black to said carbon black reactor, where the surface is non-catalytic to cracking or hydrocarbon polymerization. 38. The method of any preceding or following embodiment/feature/aspect, wherein said supply comprises providing said feedstock yielding preheated carbon black through at least one feedstock supply pipeline feeding said feedstock carbon black reactor, and said method further comprises periodic feeding a purge gas comprising an oxidant to carbon through the at least one feed charge supply line yielding carbon black. 39. The method of any preceding or following embodiment/feature/aspect, wherein said supply comprises feeding said feedstock yielding preheated carbon black through at least one feedstock supply pipe which feeds said carbon black reactor, and said method further comprises injecting the preheated carbon black yielding feedstock into the carbon black reactor with at least partial scintillation of the carbon black yielding feedstock. 40. The method of any foregoing or following embodiment/feature/aspect, further comprising combining the feedstock yielding preheated carbon black and the stream of heated gas in the carbon black reactor to continuously form carbon black. smoke in the reactor for at least about 12 hours. 41. A method for producing carbon black comprising: introducing a stream of heated gas into a carbon black reactor; supplying at least one feedstock yielding carbon black having a first temperature below 450°C to the at least one heater; preheating said at least one carbon black yielding feedstock in said at least one heater at a second temperature greater than about 450°C to provide a preheated carbon black yielding feedstock, wherein ( a) the at least one feed charge yielding carbon black has a velocity in said at least one heater that is at least 0.2 m/sec, and the velocity is calculated based on a feed charge density measured at 60°C at 1 atm (101.33 kPa) and the smallest cross-sectional area of a feed load piping present in said at least one heater, and (b) at least one feed load yielding black of smoke has a first feed charge residence time in said heater of from 10 seconds to about 120 minutes; supplying the feedstock yielding preheated carbon black to at least one feedstock introduction point to the carbon black reactor, wherein said feedstock yielding preheated carbon black has a second residence time of feed load since leaving said at least one heater stops immediately before the point of introduction to said carbon black reactor of less than about 120 minutes, and wherein said first feed load residence time is said second combined power load residence time is 120 minutes or less; combining at least said feedstock yielding preheated carbon black through at least the point of introduction to said carbon black reactor with the heated gas stream to form a reaction stream where carbon black is formed in the said carbon black reactor; and recovering (eg, quenching) the carbon black in the reaction stream. 42. The method of any foregoing or following embodiment/feature/aspect, further comprising pressurizing said feedstock yielding carbon black to a pressure of from about 2,000 kPa to about 18,000 kPa prior to enter said at least one heater. 43. The method of any foregoing or following embodiment/feature/aspect, further comprising pressurizing said feedstock yielding carbon black to have a pressure of from about 3,000 kPa to about 18,000 kPa prior to enter said at least one heater. 44. The method of any foregoing or following embodiment/feature/aspect, further comprising pressurizing said feed charge yielding carbon black at a bar pressure between about 4,000 kPa to about 18,000 kPa before entering in said at least one heater. 45. The method of any preceding or following embodiment/feature/aspect, wherein said velocity is at least about 1 m/sec. 46. The method of any preceding or following embodiment/feature/aspect, wherein said velocity is at least about 1.6 m/sec. 47. The method of any preceding or following embodiment/feature/aspect, wherein said feedstock yielding carbon black comprises settling oil, coal tar product, ethylene cracking residue, asphaltene-containing oil, or any combination of these. 48. The method of any preceding or following embodiment/feature/aspect, wherein said feedstock yielding carbon black has an initial boiling point of from about 160°C to about 500°C. 49. The method of any preceding or following embodiment/feature/aspect, wherein said preheating at least one feedstock yielding carbon black comprises heating said feedstock yielding carbon black in said heater having a heat exchanger operating at an average heat flow from about 20 kW/m2 to about 150 kW/m2. 50. The method of any preceding or following embodiment/feature/aspect, wherein at least a portion of said preheating takes place in said at least one heater which has its heat supplied, at least partially, by heat generated by the said carbon black reactor or another carbon black reactor or both. 51. The method of any preceding or following embodiment/feature/aspect, wherein said first residence time and second residence time combined are less than 60 minutes. 52. The method of any preceding or following embodiment/feature/aspect, wherein said at least one heater exchanges heat with at least a portion of said carbon black reactor. 53. The method of any preceding or following embodiment/feature/aspect, wherein said at least one heater contacts said reaction stream in said carbon black reactor downstream of a flash cooler, wherein said at least one heater comprises a heat exchanger, with walls heated by said reaction stream on a first side thereof and contacting said feed charge yielding carbon black on an opposite side thereof before said feed charge yielding carbon black. 54. The method of any preceding or following embodiment/feature/aspect, wherein said at least one heater includes a heat exchanger which exchanges heat with said reaction stream in said carbon black reactor, wherein a flowable heat flowing through the heat exchanger is heated, and the flowable heated heat carrier passes through said at least one heater positioned external to the reactor and operable to exchange heat from the flowable heat carrier with the feed load to heat the reactor. said feed load yielding carbon black. 55. The method of any preceding or following embodiment/feature/aspect, wherein said at least one heater is at least partially heated with carbon black tail gas from said carbon black reactor or a carbon black reactor of different carbon, or both, to heat the feedstock yielding carbon black. 56. The method of any preceding or following embodiment/feature/aspect, wherein introducing the heated gas stream comprises plasma heating a plasma heated gas stream in a plasma heater to provide at least a portion of the heated gas stream. 57. The method of any preceding or following embodiment/feature/aspect, further comprising providing a non-catalytic surface on the walls contacting the feed load yielding carbon black from said at least one heater and inner walls of at least a feedstock supply pipeline that supplies said feedstock yielding preheated carbon black to said carbon black reactor, where the surface is non-catalytic to cracking or hydrocarbon polymerization. 58. The method of any preceding or following embodiment/feature/aspect, wherein said supply comprises providing said feedstock yielding preheated carbon black through at least one feedstock supply pipeline which feeds said carbon black reactor, and said method further comprising periodically feeding a purge gas comprising an oxidant to carbon through the at least one feed charge supply line yielding carbon black. 59. The method of any preceding or following embodiment/feature/aspect, wherein said supply comprises feeding said feedstock yielding preheated carbon black through at least one feedstock supply pipeline which feeds said carbon black reactor, and said method further comprises injecting the preheated carbon black yielding feedstock into the carbon black reactor with at least partial scintillation of the carbon black yielding feedstock. 60. The method of any preceding or following embodiment/feature/aspect, further comprising combining the feedstock yielding preheated carbon black and the stream of heated gas in the carbon black reactor to continuously form carbon black. smoke in the reactor for at least about 12 hours. 61. A method for producing carbon black comprising: introducing a stream of heated gas into a carbon black reactor; supplying at least one feedstock yielding carbon black having a first temperature below 300°C to at least one heater at a first pressure of greater than 1000 kPa; preheating said at least one carbon black yielding feedstock in said at least one heater to a second temperature greater than about 300°C to provide a preheated carbon black yielding feedstock, wherein ( a) the at least one feedstock yielding carbon black has a second pressure in said at least one heater that is approximately the same as or less than said first pressure, as calculated based on the assumption of the same cross-sectional area as that of the feed charge runs during the first press and second press and (b) the at least one feed charge yielding carbon black has a first feed charge residence time in said heater of less than about 120 minutes; supplying said preheated carbon black feedstock to at least one feedstock introduction point in the carbon black reactor, wherein said feedstock yielding preheated carbon black exhibits a second residence time of feed load since leaving said at least one heater stops immediately before the point of introduction to said carbon black reactor of less than about 120 minutes, and wherein said first feed load residence time is said second time combined power load residency is 120 minutes or less; combining at least said feedstock yielding preheated carbon black through at least the point of introduction to said carbon black reactor with the heated gas stream to form a reaction stream where carbon black is formed in the said carbon black reactor; and recovering (eg, quenching) the carbon black in the reaction stream. 62. A method for producing carbon black comprising: introducing a stream of heated gas into a carbon black reactor; supplying at least one feedstock yielding carbon black having a first temperature below 300°C to at least one heater at a first pressure of greater than 1000 kPa; preheating said at least one carbon black yielding feed in said at least one heater at a second temperature of greater than about 300°C to provide a carbon black yielding feedstock, where the carbon at least at least one feedstock yielding carbon black has i) a second pressure in said at least one heater that is approximately the same as or less than said first pressure first, and ii) the at least one feedstock yielding carbon black has a velocity in said at least one heater that is at least 0.2 m/sec, and the velocity is calculated based on a feed charge density measured at 60°C at 1 atm and the smallest cross-sectional area of a feed load pipeline present in said at least one heater, and where i) is calculated based on the same cross-sectional area in which the feed load moves during the first press and the second press; and supplying the feedstock yielding preheated carbon black to at least one feedstock introduction point to the carbon black reactor, combining at least said feedstock yielding preheated carbon black through at least minus the point of introduction to said carbon black reactor with the heated gas stream to form a reaction stream where carbon black is formed in said carbon black reactor; and recovering (eg, quenching) the carbon black in the reaction stream. 63. An apparatus for producing carbon black comprising: a reactor for combining a stream of heated gas and at least one feed charge yielding carbon black to form a reaction stream where carbon black is formed in the reactor ; at least one feedstock supply pipeline for the feedstock supply yielding carbon black to at least one feedstock introduction point to the reactor to combine the feedstock with the heated gas stream; at least one feedstock heater operable to preheat the feedstock yielding carbon black supplied in the supply pipeline from the at least one feedstock to a temperature of at least about 300°C; at least one pump operable to pressurize the feedstock yielding carbon black at a pressure greater than about 1000 kPa before the feedstock is preheated to at least about 300°C and to provide a feedrate rate of the feed load supplied to the feed load heater, at least one of at least 0.2 m/s, where the speed is calculated based on a feed load density measured at 60°C at 1 atm and the the smallest cross-sectional area of a feed load piping present in said at least one heater; and optionally, a quench cooler for quenching the carbon black in the reaction stream; wherein said apparatus is further operable to provide a residence time of feedstock in the at least one feedload heater and in the at least one feedload supply pipeline prior to introduction into the reactor of the preheated feedstock. at least about 300°C which is less than about 120 minutes. 64. The apparatus of any preceding or following embodiment/feature/aspect, wherein the at least one feed charge heater comprises a heat exchanger operable to heat the feed charge yielding carbon black at an average heat flux greater than about 10 kW/m2. 65. Apparatus of any preceding or following embodiment/feature/aspect, wherein at least one heater of a feed load is positioned within the reactor to be contacted by the operable reaction current to heat the feed load to a temperature of at least 300°C. 66. Apparatus of any preceding or following embodiment/feature/aspect wherein the at least one feed load heater is positioned in contact with at least a portion of the reactor operable to heat the feed load to a temperature of at least minus 300°C. 67. Apparatus of any foregoing or following embodiment/feature/aspect, wherein the at least one feed load heater comprises a heat exchanger disposed within the downstream chiller reactor, wherein said heat exchanger comprises walls adapted to be heated by the reaction stream on their first side and adapted to be contacted by the feed load on an opposite side thereof before the feed load is supplied to at least one supply pipeline, where the feed load is heated to a temperature of at least 300°C in the heat exchanger. 68. The apparatus of any foregoing or following embodiment/feature/aspect, further comprising a heat exchanger for a flowable heat carrier positioned within the reactor to be reaction-current-countable, and the at least one feed load is external to the reactor and operable to exchange heat from the flowable heat carrier which has exited the heat exchanger with the feed load in the feed load heater to heat the feed load to a temperature of at least 300°C . 69. The apparatus of any preceding or following embodiment/feature/aspect, wherein the at least one feed charge heater is operable to exchange heat from a reactor waste gas stream to heat the feed charge to a temperature of at least 300°C. 70. The apparatus of any foregoing or following embodiment/feature/aspect, further comprising a plasma heater operable to heat a plasma gas stream that can be heated to provide at least a portion of the heated gas stream. 71. Apparatus of any foregoing or following embodiment/feature/aspect, further comprising non-catalytic surface on walls contacting the feed load of the feed load heater and inner walls contacting the feed load of at least one pipeline supply feedstock, where the surface is non-catalytic with respect to cracking or hydrocarbon polymerization. 72. Apparatus of any foregoing or following embodiment/feature/aspect, further comprising a non-catalytic ceramic coating on the walls contacting the feed load of the feed load heater and inner walls contacting the feed load of at least a supply pipe for the power load. 73. The apparatus of any foregoing or following embodiment/feature/aspect, further comprising at least one purge gas source comprising an oxidant to carbon and at least one purge gas introduction point in the at least a feed load supply line operable to periodically flush the at least one feed load supply line with the purge gas. 74. The apparatus of any preceding or following embodiment/feature/aspect, wherein said reactor is operable to combine feed load and heated gas stream to continuously form carbon black in the reactor for at least about 12 hours. 75. The method of any preceding or following embodiment/feature/aspect, wherein said preheating prevents the formation of a vapor film on said at least one heater and/or prior to supplying said carbon black reactor smoke. 76. The method of any preceding or following embodiment/feature/aspect, wherein said preheating and/or said supply is performed in the absence of a leak pressure drop based on steady-state operating conditions. 77. Carbon black formed by the method of any preceding or following embodiment/characteristic/aspect. 78. Carbon black of any preceding or following embodiment/characteristic/appearance, wherein said carbon black has at least a 10% lower amount of PAH compared to a carbon black of the same morphology manufactured in a method without preheating the power supply. 79. Carbon black of any foregoing or following embodiment/characteristic/aspect, wherein said carbon black has a high percentage of PAH MW amount based on the total amount of PAH at least 10% lower compared to a carbon black of the same morphology manufactured in a method without said preheating. 80. A method for producing carbon black, comprising: introducing a stream of heated gas into the carbon black reactor; supplying at least one carbon black yielding feed to the at least one heater; preheating said at least one carbon black yielding feed in said at least one heater at a second temperature greater than about 300°C to provide a preheated carbon black yielding feedstock, wherein ( a) at least one feedstock yielding carbon black has a velocity in said at least one heater that is at least 0.2 m/s and the velocity is calculated based on the feedstock density measured at 60°C in 1 atm and the smallest cross-sectional area of a feed charge pipeline present in said at least one heater and (b) at least one feed charge yielding carbon black exhibits a first feed charge residence time in said heater. at least about 120 minutes; supplying a preheated carbon black-yielding feedstock to at least one carbon black introduction point to the carbon black reactor, wherein said preheated carbon black-yielding feedstock exhibits a second residence time leaving said at least one heater for just before the point of introduction to said carbon black reactor of less than about 120 minutes; and wherein said first feed load residence time and said second feed load residence time combined are 120 minutes or less; wherein said preheat is at a pressure sufficient to prevent the formation of a vapor film on said at least one heater or prior to said supply to said carbon black reactor; combining at least said feedstock yielding preheated carbon black through at least one point of introduction to said carbon black reactor with the heated gas stream to form a reaction stream in which the carbon black is formed in said carbon black reactor; and recovering the carbon black in the reaction stream.

The present invention may include any combination of these features or embodiments above and/or below as set forth in the sentences and/or paragraphs. Any combination of the features disclosed in the present invention is considered part of the present invention and is not intended to limit the combinable features.

The present invention will be better illustrated by the following examples which are intended to exemplify the invention.

EXAMPLES Example 1

Computer-based modeling was used to estimate potential raw material cost savings for two carbon black grades (A and B) using feed load temperatures of 215°C, 500°C, and 700° C in a carbon black production scheme capable of stable continuous operation at 500°C and 700°C through the indicated fouling control approaches of the present invention. The computer modeling program Aspen Plus was used to model the process system, using methodologies and assumptions for mass and energy balances and reaction chemistry in accordance with acceptable practices in the industries. The flowchart model used for this modeling is similar to that shown in Figure 5. Figure 5 shows the process schematic for Class A and a feed load preheated temperature of 500°C and this general process layout for another shape also applies to other combinations of Modeled Feed Load Temperature and Ratings. The process scheme shown in detail in Figure 5 is generally similar to the process scheme shown in Figure 1. As shown in Figure 5, the feed load is heated using the smoke heat from the carbon black reactor between an initial quench and a secondary quenching location. Heat load capacity used in the calculation is shown in figure 6. Feed load was assumed to be non-reactive, the endothermic effect of the pyrolysis reaction is not included in the load load heating capacity. Two cases with preheated feed load temperatures of 500°C and 700°C were modeled and compared with baseline cases (215°C preheat) for Class A and B.

The feedstocks yielding liquid carbon applicable to Grades A and B used in the modeling were settling oil/coal tar blend. Grade A and B liquid feedstocks had the following compositions: Grade A settling oil: Highest heating value [J/kg]: 39,524,446 Final analysis [% by mass]: ASH 0 CARBON 88.68 HYDROGEN 6.92 NITROGEN 0.31 CHLORINE 0 SULFUR 3.86 OXYGEN 0.23 Class B decanting oil/coal tar Flow rate [kg/h]: 3.562 Heat of Formation [J/kg]: 50,692 Highest Heating Value [J/kg]: 39,878,687 Higher Heating Value [J/kg]: 39,878,687 Final analysis [% by mass]: ASH 0 CARBON 88.62 HYDROGEN 7.40 NITROGEN 0.31 CHLORINE 0 SULFUR 3.44 OXYGEN 0, 23 Coal tar [% by mass]: 30.0

Tabela 3 (CB Classificação A: Temp. 500°C)

Tabela 4 (CB Classificação A: Temp . 700°C)

Tabela 5 (CB Classificação B: Temp. 500°C)

Tabela 6 (CB Classificação B: Temp. 7000°C)

Tabela 7

Tables 2 through 7 show the raw data used for the modeling calculations for each carbon black classification at each temperature of the 500 °C and 700 °C preheat temperatures. The results of the modeling calculations are also presented in the Tables. Table 2 Energy content of raw materials and carbon black in Aspen Plus calculations

Table 3 (CB Classification A: Temp. 500°C)

Table 4 (CB Classification A: Temp. 700°C)

Table 5 (CB Classification B: Temp. 500°C)

Table 6 (CB Classification B: Temp. 7000°C)

Table 7

As shown by the results, raw material cost savings of more than 10% can be achieved when the feed load is preheated to 500°C and greater than 20% when the feed load is preheated to 700°C. °C in a stable mode without feed load fouling, compared to processing at a lower conventional feed load temperature of 215 °C. The "CB Yield" and some others in Table 7 use the conventional feed load temperature of 215°C as the baseline (100%) and comparing the higher temperature preheated feed loads to this line of base. As indicated, the fouling control approaches of the present invention make it possible to operate at higher feed load temperatures such as, including industrial scale operations. In Table 7, the reactor energy efficiency (GER) is defined as a ratio between the heating value of the produced material to the combined energy input, which includes the feed load (FS) and burner fuel heating values and Electricity ETR = (HHV-CB)/(HHV-power load + HHV-Natural Gas + kWh/kg of Electric Power-CB). In Table 7, burner stoichiometry is defined as a percentage of burner airflow to burner stoichiometric airflow (airflow required for complete combustion of the burner fuel).

The benefits stated in this model would be achieved with any carbon black, such as any ASTM rating such as N100 to N1000 and the like. Modeling will show the same benefits.

Example 2

In these examples, nine tests were performed to demonstrate examples of heating the feedstock yielding carbon black from 70°C to about 500°C using samples from different feedstocks, as explained further below. The different operating parameters are shown in Table 8 and also the type of power load used is shown in Table 8 and the details of the power load are shown in Table 9. As can be seen in Table 8 following the present invention, the feedstock yielding carbon black can be preheated to temperatures in the range of 500°C or more and still achieve successful and continuous production of carbon black. On the carbon black formed from test numbers 2-5, 8 and 9 analysis was performed and determined that the carbon black was acceptable for commercial use as a carbon black based on morphology, purity and the like. It was determined that an advantage of these manufactured carbon blacks of the present invention was that PAH levels of carbon blacks were on the order of about 50% less PAH (on a ppm level) than conventional blacks of the same morphology. Thus, an additional advantage of the present invention is the ability to form commercially acceptable carbon blacks with a much smaller amount of PAH. The determination of PAH was based on a determination of PAH-20 as understood in the art.

As further defined in Table 8 below, the entry for "drop in leak pressure" indicates whether vapor film and/or coke has formed or is about to form or not. When an inlet reads "NO" it means that no leakage pressure drop was detected and in fact the test was considered a success as commercially acceptable carbon black is produced with no coking and no vapor film for the heater lines or supply lines. When the input for the leakage pressure drop reads "YES", this is an indication that there has been a rapid pressure drop from steady state operating conditions during the manufacture of carbon black and is a clear indication that the carbon black film steam was taking place and that coking in the appliance was unavoidable. In fact, in Test #1, to confirm this understanding, a leak pressure drop was seen in Test #1, and ultimately, in the analysis of the feed charge heater parts, coke was detected visually in the pipelines. heater, which confirming the leak pressure drop was an indication of inevitable coke formation.

Examples 2-5, 8 and 9 clearly show that carbon black can be manufactured using high temperature feedstocks and still prevent the formation of vapor and coke film leading to a commercially acceptable carbon black product.

In Examples 1, 6 and 7, where the leakage pressure drop was identified and where coking occurred in Test number 1, by employing the present invention, these tests can be adjusted to avoid a leakage pressure drop and therefore, forming a film of steam and/or coke by adjusting the heating inlet pressure or raising the heating inlet pressure and/or increasing the oil inlet velocity and/or reducing the residence time in the heater. By raising the heater inlet pressure, for example by 10% or more, this would have an effect on not forming vapors in the heater during preheating of the preheated carbon black feedstock. Essentially, any combination of adjusting heating inlet pressure (typically by increasing pressure), increasing oil inlet velocity, and/or decreasing residence time can reduce vapor formation and/or eliminate vapor formation. and therefore prevent a drop in leakage pressure.

* Presença de coqueificação confirmada. ** Experimento parou imediatamente para evitar danos ao aquecedor/reator Tabela 9

In the following examples, in Examples 2-5, 8 and 9, an improvement in carbon black yield (% by weight) was achieved compared to carbon black manufactured using a conventional feed temperature of 215°C as baseline (100%) and comparing the highest preheated feed loads to that baseline. The yield of carbon black improved from 4% to 8% (by weight) in these examples. In addition, the examples of the present invention provided an energy savings of 7% to 11% over carbon black manufactured using the conventional feed load temperature of 215°C as the baseline (100%) and comparing the energy used for preheated power loads from higher temperatures to that baseline. Thus, the present invention provides a higher yield of carbon black and uses less energy to obtain the same, this being superior to conventional processes and also unexpected. Table 8

* Presence of coking confirmed. ** Experiment stopped immediately to prevent heater/reactor damage Table 9

Applicants specifically incorporate the complete contents of all references cited in this disclosure. Furthermore, where an amount, concentration, or other value or parameter is given either as a range, preferred range or a list of most preferred values and least preferred values, it is to be understood as meaning especially all ranges formed from any pair of any upper range limit or preferred value and any lower range limit or preferred value, regardless of whether the ranges are revealed separately. Whenever a range of numerical values is recited in this document, unless otherwise stated, the range is intended to include the endpoints thereof, and all integers and fractions within the range. It is not intended that the scope of the invention be limited to the specific values recited when defining a range.

Other embodiments of the present invention will become apparent to those skilled in the art from a consideration of the present specification and practice of the present invention disclosed herein. It is intended that the present specification and examples be considered as exemplary only with the true scope and spirit of the invention being indicated by the following claims and their equivalents.

Claims (67)

1. Method for producing carbon black characterized in that it comprises: introducing a stream of heated gas into a carbon black reactor; providing at least one carbon black yielding feed to the at least one heater; preheating said at least one feedstock yielding carbon black in said at least one heater at a temperature greater than 300°C to provide a preheated feedstock yielding carbon black, wherein (a) at least one feed charge yielding carbon black has a velocity through said at least one heater of about 1.0 m/sec or greater at the smallest cross-sectional area of a feed charge pipeline in said heater, where the velocity is a average velocity calculated based on a measured feed charge density at 60°C in 1 atm and (b) at least one feed charge yielding carbon black has a first feed charge residence time in said heater of less than approx. of 120 minutes; supplying said preheated feedstock yielding carbon black having said temperature greater than 300°C to at least one point of introduction of the feedstock yielding to the carbon black reactor, wherein said feedstock yielding carbon black preheated having said temperature greater than 300°C has a second feed load residence time, provided that said at least one heater leaves said at least one heater to the point of introduction to said carbon black reactor, of less than about 120 minutes ; and wherein said first feed load residence time and said second feed load residence time combined are 120 minutes or less; whereby vapor film formation is controlled at said at least one heater and prior to said supply to said carbon black reactor; combining at least said feedstock yielding preheated carbon black through at least one point of introduction to said carbon black reactor with the heated gas stream to form a reaction stream in which the carbon black is formed in said carbon black reactor; and recovering the carbon black in the reaction stream, and wherein said carbon black is furnace carbon black and said carbon black reactor is a furnace carbon black reactor, and said feedstock yielding carbon black has an initial boiling point of about 160°C to about 600°C. 2. Method according to claim 1, characterized in that it additionally comprises pressurizing said feed charge yielding carbon black so as to have a pressure greater than 1,000 kPa before entering said at least one heater . 3. Method according to claim 1, characterized in that it additionally comprises pressurizing said feed charge yielding carbon black so as to have a pressure greater than 2,000 kPa before entering said at least one heater . A method as claimed in claim 1, characterized in that it additionally comprises pressurizing said feed charge yielding carbon black at a pressure of about 2,000 kPa to 18,000 kPa before entering said at least one heater. 5. Method according to claim 1, characterized in that said speed is at least 1.6 m/s. 6. The method of claim 1, wherein said feedstock yielding carbon black comprises settling oil, coal tar product, ethylene cracking residue, asphaltene-containing oil, or any combination thereof . A method according to claim 1, characterized in that said preheating of at least one feed charge yielding carbon black comprises heating said feed charge yielding carbon black in said heater having a heat exchanger operating at an average heat flow greater than about 10 kW/m2. A method according to claim 1, characterized in that at least a portion of said preheating takes place in said at least one heater that has heat supplied, at least partially, by the heat generated by said black reactor. smoke or other carbon black reactor or both. 9. Method according to claim 1, characterized in that said first residence time and said second residence time combined are less than 60 minutes. A method according to claim 1, characterized in that said at least one heater is in heat exchange with at least a portion of said carbon black reactor. A method according to claim 1, characterized in that said at least one heater contacts said reaction stream in said carbon black reactor downstream of a flash cooler, wherein said at least one heater comprises a heat exchanger having walls heated by said reaction stream on a first side thereof and contacting said feed charge yielding carbon black on an opposite side thereof. A method according to claim 1, characterized in that said at least one heater includes a heat exchanger that exchanges heat with said reaction stream in said carbon black reactor, wherein a flowable heat carrier flowing through the heat exchanger is heated, and the flowable heated heat carrier passes through said at least one heater positioned external to the reactor and operable for exchanging heat from the flowable heat carrier with the feed load to heat said power load yielding carbon black. Method according to claim 1, characterized in that said at least one heater is at least partially heated with carbon black waste gas from said carbon black reactor or from a different carbon black reactor. , or both, to heat the feedstock yielding carbon black. A method according to claim 1, characterized in that it further comprises providing a non-catalytic surface on the walls that contact the feed load yielding carbon black from said at least one heater and on the inner walls of at least one feedstock supply pipeline that supplies said feedstock yielding preheated carbon black to said carbon black reactor, wherein the surface is non-catalytic to cracking or hydrocarbon polymerization. A method according to claim 1, characterized in that said supply comprises feeding said feedstock yielding preheated carbon black through at least one feedstock supply pipe that feeds said carbon black reactor, and said method further comprises periodically feeding a purge gas comprising an oxidant to carbon through the at least one feed charge supply line yielding carbon black. A method according to claim 1, characterized in that said supply comprises feeding said feedstock yielding preheated carbon black through at least one feedstock supply pipe that feeds said carbon black reactor, and said method further comprises injecting the preheated feedstock yielding carbon black into the carbon black reactor with at least partial scintillation of the feedstock yielding carbon black. A method as claimed in claim 1, characterized in that it further comprises combining the feed charge yielding preheated carbon black and the heated gas stream in the carbon black reactor to continuously form carbon black. smoke in the reactor for at least about 12 hours. 18. Method according to claim 1, characterized in that said preheating and said supply are in the absence of a leak pressure drop based on steady state operating conditions. A method according to claim 1, characterized in that said at least one feed charge yielding carbon black has a first temperature below 360°C when supplying said at least one heater; and said preheating said at least one feedstock yielding carbon black in said at least one heater being said second temperature from 360°C to 850°C and said at least one feedstock yielding carbon black has said first feed charge residence time and said second feed charge residence time combined in said heater from about 10 seconds to about 120 minutes. Method according to claim 19, characterized in that it additionally comprises pressurizing said feed charge yielding carbon black so as to have a pressure greater than 2,000 kPa before entering said at least one heater. . A method as claimed in claim 19, characterized in that it additionally comprises pressurizing said feed charge yielding carbon black so as to have a pressure greater than about 3,000 kPa before entering said at least a heater. A method as claimed in claim 19, characterized in that it further comprises pressurizing said feed charge yielding carbon black at a pressure of from about 3,000 kPa to about 18,000 kPa before entering said at least minus one heater. 23. Method according to claim 19, characterized in that said speed is at least about 1.6 m/s. 24. The method of claim 19, wherein said feedstock yielding carbon black comprises settling oil, coal tar product, ethylene cracking residue, asphaltene-containing oil, or any combination thereof . Method according to claim 19, characterized in that said preheating of the at least one feed charge yielding carbon black comprises heating said feed charge yielding carbon black in said heater having an exchanger of heat operating at an average heat flux greater than about 20 kW/m2. A method according to claim 19, characterized in that at least a portion of said preheating takes place in said at least one heater that has heat supplied, at least partially, by the heat generated by said black reactor. smoke, or another carbon black reactor, or both. 27. Method according to claim 19, characterized in that said first residence time and said second residence time combined are less than 60 minutes. A method according to claim 19, characterized in that said at least one heater is exchanging heat with at least a portion of said carbon black reactor. A method according to claim 19, characterized in that said at least one heater contacts said reaction stream in said carbon black reactor downstream of a flash cooler, wherein said at least one heater comprises a heat exchanger having walls heated by said reaction stream on a first side thereof and contacting said feed charge yielding carbon black on an opposite side thereof before said feed charge yielding carbon black. A method according to claim 19, characterized in that said at least one heater includes a heat exchanger that exchanges heat with said reaction stream in said carbon black reactor, wherein a heat carrier flowable heat exchanger flowing through the heat exchanger is heated, and the flowable heated heat carrier passes through said at least one heater positioned external to the reactor and operable to exchange heat from the flowable heat carrier with the feed load to heat said power load yielding carbon black. A method according to claim 19, characterized in that said at least one heater is at least partially heated with carbon black tail gas from said carbon black reactor, or a carbon black reactor. different smoke, or both, to heat the feedstock yielding carbon black. A method according to claim 19, characterized in that it further comprises providing a non-catalytic surface on the walls contacting the feed load yielding carbon black from said at least one heater and on the inner walls of at least one heater. a feedstock supply pipeline that supplies said feedstock yielding preheated carbon black to said carbon black reactor, where the surface is non-catalytic to cracking or hydrocarbon polymerization. A method as claimed in claim 19, characterized in that said supply comprises feeding said feedstock yielding preheated carbon black through at least one feedstock supply pipeline that feeds said carbon black reactor, and said method further comprises periodically feeding a purge gas comprising an oxidant to carbon through the at least one feed charge supply line yielding carbon black. A method according to claim 19, characterized in that said supply comprises feeding said feedstock yielding preheated carbon black through at least one feedstock supply pipe that feeds said carbon black reactor, and said method further comprises injecting the preheated feedstock yielding carbon black into the carbon black reactor with at least partial scintillation of the feedstock yielding carbon black. A method as claimed in claim 19, characterized in that it further comprises combining the feedstock yielding preheated carbon black and the stream of heated gas in the carbon black reactor to continuously form carbon black. smoke in the reactor for at least about 12 hours. A method as claimed in claim 1, characterized in that said at least one feed charge yielding carbon black has a first temperature below 450°C when supplying said at least one heater; and said preheating said at least one feedstock yielding carbon black in said at least one heater being said second temperature greater than 450°C and said at least one feedstock yielding carbon black having said first feed load residence time in said heater is from 10 seconds to about 120 minutes. A method as claimed in claim 36, characterized in that it additionally comprises pressurizing said feed charge yielding carbon black so as to have a pressure of from about 2,000 kPa to about 18,000 kPa before entering in said at least one heater. A method as claimed in claim 36, characterized in that it further comprises pressurizing said feed charge yielding carbon black so as to have a pressure of from about 3,000 kPa to about 18,000 kPa before entering in said at least one heater. A method as claimed in claim 36, characterized in that it further comprises pressurizing said feed charge yielding carbon black at a pressure of 4,000 kPa to 18,000 kPa before entering said at least one heater. 40. Method according to claim 36, characterized in that said speed is at least about 1.6 m/s. 41. The method of claim 36, wherein said feedstock yielding carbon black comprises settling oil, coal tar product, ethylene cracking residue, asphaltene-containing oil, or any combination thereof . A method according to claim 36, characterized in that said preheating of at least one feed charge yielding carbon black comprises heating said feed charge yielding carbon black in said heater having a heat exchanger operating at an average heat flow from about 20 kW/m2 to about 150 kW/m2. A method as claimed in claim 36, characterized in that at least a portion of said preheating takes place in said at least one heater that has heat, at least partially, provided by the heat generated by said black reactor. smoke, or another carbon black reactor, or both. 44. Method according to claim 36, characterized in that said first residence time and said second residence time combined are less than 60 minutes. A method according to claim 36, characterized in that said at least one heater is exchanging heat with at least a portion of said carbon black reactor. A method according to claim 36, characterized in that said at least one heater contacts said reaction stream in said carbon black reactor downstream of a flash cooler, wherein said at least one heater comprises a heat exchanger having walls heated by said reaction stream on a first side thereof and contacting said feed charge yielding carbon black on an opposite side thereof before said feed charge yielding carbon black. A method according to claim 36, characterized in that said at least one heater includes a heat exchanger that exchanges heat with said reaction stream in said carbon black reactor, wherein a flowable heat carrier that flowing through the heat exchanger is heated, and the flowable heated heat carrier passes through said at least one heater positioned external to the reactor and operable for exchanging heat from the flowable heat carrier with the feed load to heat said load power supply rendering carbon black. A method according to claim 36, characterized in that said at least one heater is at least partially heated with carbon black tail gas from said carbon black reactor, or from a carbon black reactor. of different carbon, or both, to heat the feedstock yielding carbon black. A method as claimed in claim 36, characterized in that it further comprises providing a non-catalytic surface on the walls contacting the feed load yielding carbon black from said at least one heater and on the inner walls of at least one heater. at least one feedstock supply pipeline that supplies said feedstock yielding preheated carbon black to said carbon black reactor, wherein the surface is non-catalytic to cracking or hydrocarbon polymerization. A method according to claim 36, characterized in that said supply comprises feeding said feedstock yielding preheated carbon black through at least one feedstock supply pipeline that feeds said carbon black reactor, and said method further comprises periodically feeding a purge gas comprising an oxidant to carbon through the at least one feed load supply line yielding carbon black. A method as claimed in claim 36, characterized in that said supply comprises feeding said feedstock yielding preheated carbon black through at least one feedstock supply pipeline that feeds said carbon black reactor, and said method further comprises injecting the preheated carbon black-yielding feedstock into the carbon black reactor with at least partial scintillation of the carbon black-yielding feedstock. A method as claimed in claim 36, characterized in that it further comprises combining the feed charge yielding preheated carbon black and the stream of heated gas in the carbon black reactor to continuously form carbon black. smoke in the reactor for at least about 12 hours. A method according to claim 1, characterized in that said supply of said at least one feed charge yielding carbon black to said at least one heater is at a first pressure greater than 1,000 kPa and has said first temperature below 400°C; and wherein (a) the at least one feedstock yielding carbon black has a second pressure in said at least one heater that is approximately the same as or less than said first pressure, as calculated based on the assumption of the same section area transversal that the feed load travels during the first press and the second press. A method as claimed in claim 1, characterized in that said at least one feed charge yielding carbon black has said first temperature less than 300°C by supplying said at least one heater at a first pressure greater than 1000 kPa; and wherein the at least one carbon black yielding feedstock has i) a second pressure in said at least one heater that is about the same or less than said first pressure and wherein i) is calculated based on the same area cross-section in which the feed load moves during the first press and the second press; and wherein said supply of said feedstock yielding carbon black preheated to a temperature greater than 300°C at said pressure controls vapor film formation in said at least one heater and prior to said supply to said steam reactor. smoke black. A method according to claim 1, characterized in that said feedstock yielding carbon black preheated to a temperature greater than 300°C is at a pressure sufficient to control vapor film formation in said at least one heater and prior to said supply of carbon black to said reactor. 56. Apparatus for producing carbon black by the method as defined in claim 1, the apparatus characterized in that it comprises: a reactor for combining a stream of heated gas and at least one feed charge yielding carbon black to form a reaction stream in which carbon black is formed in the reactor; at least one feedstock supply pipeline for the feedstock supply yielding carbon black to at least one feedstock introduction point to the reactor to combine the feedstock with the heated gas stream; at least one feedstock heater operable to preheat the feedstock yielding carbon black supplied in the at least one feedstock supply pipeline to a temperature of at least about 300°C; at least one pump operable to pressurize the feedstock yielding carbon black at a pressure greater than about 1000 kPa before the feedstock is preheated to at least about 300°C and to provide a feedrate rate of the feed load supplied to the at least one feed charge heater of about 1.0 m/s or greater, where the velocity is calculated based on a feed charge density measured at 60°C at 1 atm and the smallest cross-sectional area of a feed load pipeline present in said at least one heater; and a blast chiller for cooling the carbon black in the reaction stream; wherein said apparatus is further operable to provide a feedload residence time in the at least one feedload heater and the at least one feedload supply pipeline prior to introduction into the reactor of the prefeedload -heated to at least about 300°C, which is less than about 120 minutes, wherein said preheating prevents vapor film formation on said at least one heater, and wherein said carbon black is black of furnace carbon and said carbon black reactor is a furnace carbon black reactor, and said feedstock yielding carbon black has an initial boiling point of about 160°C to about 600°C . 57. Apparatus according to claim 56, characterized in that the at least one feed charge heater comprises a heat exchanger operable to heat the feed charge yielding carbon black at an average heat flux greater than about 10 kW/m2. 58. Apparatus according to claim 56, characterized in that the at least one feed load heater is positioned within the reactor to be contacted by the operable reaction current to heat the feed load to a temperature of at least 300°C. 59. Apparatus according to claim 56, characterized in that the at least one feed load heater is positioned in contact with at least a portion of the reactor operable to heat the feed load to a temperature of at least 300°C. 60. Apparatus according to claim 56, characterized in that the at least one feed load heater comprises a heat exchanger positioned within the reactor downstream of the blast chiller, wherein said heat exchanger comprises walls adapted to be heated by the reaction stream on a first side thereof and adapted to be contacted by the feed load on an opposite side thereof before the feed load is supplied to the at least one feed load supply pipeline, wherein the feed load is heated to a temperature of at least 300°C in the heat exchanger. 61. Apparatus according to claim 56, characterized in that it additionally comprises a heat exchanger for a flowable heat carrier positioned within the reactor to be contactable by the reaction current, and the at least one charge heater The feed stream is external to the reactor and operable to exchange heat from the flowable heat carrier that has exited the heat exchanger with the feed load in the feed load heater to heat the feed load to a temperature of at least 300°C. 62. Apparatus according to claim 56, characterized in that the at least one feed load heater is operable to exchange heat from a reactor waste gas stream to heat the feed load to a temperature of at least 300°C. Apparatus as claimed in claim 56, further comprising a plasma heater operable for heating a plasma heated gas stream to provide at least a portion of the heated gas stream. 64. Apparatus according to claim 56, characterized in that it additionally comprises a non-catalytic surface on the walls contacting the feed load of the feed load heater and on the inner walls contacting the feed load of the at least one feed load supply piping, where the surface is non-catalytic to cracking or hydrocarbon polymerization. 65. Apparatus according to claim 56, characterized in that it additionally comprises a non-catalytic ceramic coating on the walls contacting the feed load of the feed load heater and on the inner walls contacting the feed load of at least a supply pipe for the power load. 66. Apparatus according to claim 56, characterized in that it additionally comprises at least one purge gas source comprising an oxidant for carbon and at least one purge gas introduction point in the at least one pipeline. load supply line operable to periodically purge the at least one load supply line with the purge gas. 67. Apparatus according to claim 56, characterized in that said reactor is operable to combine feed load and heated gas stream to continuously form carbon black in the reactor for at least 12 hours.

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